Note: Descriptions are shown in the official language in which they were submitted.
CA 02901202 2015-07-22
CONCEALED-FASTENER EXTERIOR CLADDING PANELS FOR
BUILDING CONSTRUCTION
Field of the Invention
This application relates generally to exterior cladding panels for covering
the
roof or wall of a building, and more specifically to such a panel with the
associated
screw being fastened through the underlying building frame.
Background of the Invention
All shelter buildings, whether they are houses or agricultural or commercial
structures, must be strong, stable, and weather-resistant. Such structures are
typically
framed from an assembly of interconnected wood or metal members that define
their
walls and roof line. Vertical studs and horizontal base plates and header
plates
provide structure to the walls, while defining door and window openings. A
series of
rafters and purlins provide structure to the roof while defining its ridges
and valleys.
This roof can ultimately be covered by an appropriately decorative and weather-
tight
material like asphalt, wood or slate shingles, or clay tiles. Likewise, the
walls can be
covered by a suitably decorative or weather-resistant material like wood,
brick, or
plastic siding, stone, or stucco.
Interposed usually between this exterior roofing or wall covering material and
the framing assembly are rigid panels made from plywood or other composite
materials. These rigid panels are nailed, screwed, or otherwise fastened to
the rafters
and purlins or studs. They not only provide a necessary backing support to the
exterior roofing or wall cladding material, but also they provide essential
strength to
the underlying framing assembly and its individual rafter and purlin and stud
members.
An alternative type of exterior cladding material for a roof or wall is a
panel
made from a metallic material like galvanized steel. Steel panels can be more
durable
over time than wood siding or asphalt or wood shingles. If properly surface-
treated,
metal panels are resistant to the weather elements, and are usually cheaper
than brick
or stone, particularly when installation costs are taken into account.
Moreover, the
strength provided by these rigid metal panels allow for the elimination of the
need for
the plywood or composite structural sheathing underlying the panels.
CA 02901202 2015-07-22
Corrugated wrought iron-steel panels coated with zinc (e.g., "galvanized")
have been used for a long time in the construction industry. These corrugated
metal
panels are nailed directly through the panel into the underlying wood roof
rafter and
purlin or wall stud supporting structure. However, the fastener heads directly
show
on top of the metal panels, which can interfere with the decorative appearance
of the
metal panels, especially if the fastener heads were not fastened with uniform
spacing
along the metal panels. Moreover, these exposed fastener heads must include a
rubber or elastomeric washer interposed between the fastener head and the
metal sheet
that seals the area around the fastener to reduce the penetration of moisture
from rain
or snow through the protective metal panel via the hole formed by the
fastener.
Through-fastened metal panels can be fastened anywhere across the width of
the panels. This allows wide panels on the order to 36 inches or greater to be
securely
fastened to the building's framing structure. These panels typically have a
large
corrugation called a "major rib" at each panel edge and intermittently across
the width
of the panel. These ribs give the panel strength to span, e.g., open purlins
along the
building's roof line. The major ribs are formed along the edges of the panels,
so that
one laps the other during installation to form a continuous covering for the
roof.
Fasteners are usually installed through this common rib to securely connect
the panel
assembly to the underlying framing structure. Such through-fastened panel
assembly
braces the framing members to form structural diaphragms and shear walls that
brace
the entire structure. Hence, through-fastened panels not only provide weather
protection to the building, but also form a major part of the building's
lateral load
resisting system.
U.S. Patent No. 4,193,242, issued to Vallee provides an example of such
through-fastened metal panels. In this case, the panel portions are abutted in
a side-
by-side relationship, and are screwed directly into the rafters. A cover cap
is slid into
engagement with standing flanges rising veritically from the panel edges to
conceal
the screw heads. Thus, the Vallee panel constitutes a through-fastened,
fastener-
concealed panel.
U.S. Patent Nos. 3,509,675, issued to McClain and 4,959,939, issued to
Buchanan, Jr. provide examples of through-fastened metal panels that are
overlapped
CA 02901202 2015-07-22
one edge on top of the other panel's edge, and screwed directly into the
rafters. In
both of these cases, a snap-on batten cap is used to conceal the screw heads.
U.S. Patent No. 4,266,385, issued to Oehlert constitutes a through-fastened
roofing panel design featuring a partial raised rib along its one edge and
upturned rib
wall along its other edge. When two such metal panels are placed on top of the
rafters
next to each other, nails can be driven through one panel into the underlying
rafter
along the raised rib wall, with the partial raised rib of the other panel
hooked around
the raised rib wall to complete the raised rib and conceal the nail heads.
See. While
this particular design eliminates the need for special prepositioned clips, it
does
require a more elaborately shaped end profile for the metal panels. Such
elaborate
shapes can be expensive to produce and make it difficult to stack the metal
panels
during transport or storage. See also U.S. Patent No. 4,759,165, issued to
Getoor et
al. U.S. Patent No. 3,606,720 issued to Cookson discloses two adjacent through-
fastened metal panels whose edges are hooked into each other with a batten cap
further hooking into flanged surfaces on the panels to conceal the fastener
heads.
Standing-seam metal panels are not attached directly to the roof's framing
members. The simplest standing-seam panel system consists of a flat pan with
the
edges bend up at ninety degree angles. A light-gauge metal clip hooks over the
panel
edges, and is screwed into the supporting structure. The next panel is then
installed,
partially hiding the attachment clip. A batten is snapped over the seam to
complete
the rib. Because the clips indirectly attach the panels to the framing
members, such
standing-seam panels "float" along the roof. See, e.g., U.S. Patent No.
2,356,833
issued to Doe.
U.S. Patent No. 2,150,130, issued to Ragsdale et al., shows removable wall
panels consisting of multiple raised metal panels having horizontally disposed
edges.
The edge of one panel is placed on top of the edge of the next panel, and a
spring clip
is then secured on top of the panel edges and bolted into the underlying
structural wall
member to hold the metal panels in place. A cap having a similar shape to the
spring
clip's shape is then snap-fitted over the clip to conceal the bolt heads.
In other cases, a series of clips are positioned underneath the standing-scam
panels, and therefore must be secured in precise locations along the rafters.
See U.S.
3
CA 02901202 2015-07-22
Patent No. 4,590,730, issued to Blendick in which two secondary clips secure
the
metal panels edges to the primary clip that was secured to the rafter. A
batten fits
over the clips to conceal the nail head. See also U.S. Patent No. 4,400,924,
issued to
Andrews where a panel is positioned on top of the rafters, clips are installed
in place
to capture the leading edge of the panel, then the next panel is placed by
rotating its
specially diagonally upturned edges snap-fitted into engagement with the
flanges of
the clips. Finally, a batten cover is snap-fitted over the clips and into
engagement
with the upturned edges of the metal panels to conceal the nail heads. .
U.S. Patent
Nos. 5,152,115 and 5,187,911 issued to Cotter disclose a standing¨seam
roofing/cladding system that relies upon both clips and interlocking edges of
adjacent
metal panels to secure them by means of screws to the underlying rafters or
studs. A
separate batten cap is still required to conceal the screw heads.
However, such standing-seam panels require the usage of a plurality of special
clips above and beyond the metal panels, themselves. Moreover, many of them
require these clips to be precisely positioned along the rafters before the
metal panels
are laid down on the rafters, which slows down the roof assembly process.
Furthermore, the clips used to attach the standing-seam panels occur only at
the panel
edges. This limits the width of the panels to roughly 18 inches for vertical-
leg panels,
and 24 inches for trapezoidally-seamed panels. Still another disadvantage of
standing-seam panels is the fact that they cannot brace the framing structure
of the
building in the way that through-fastened panels do. Furthermore, standing-
seam
panels cannot form a structural diaphragm, and therefore are not part of the
building's
lateral load system.
U.S. Patent No. 7,104,020 issued to Suttle discloses a standing beam
structural
panel. Each panel has multiple ribs formed into it. The edges of adjacent
panels are
overlapped, and screwed directly against the rafters. A sealing cap is then
secured
around the top of the edge ribs and intermediate ribs to conceal the screw
heads, and
provide a uniform appearance to the panel assembly.
Still other metal panel products known in the art provide raised ribs for
decorative purposes. The edges of the adjacent panels are positioned either
side-by-
side or in an overlapped relationship to form a raised rib volume with a
separate piece
of wood cleating used to fill this volume, and provide a raised surface onto
which the
4
CA 02901202 2015-07-22
panel edges can be nailed. See, e.g., U.S. Patent Nos. 511,386 issued to
White, and
2,358,733 issued to Overly. However, these wood cleats must be fastened to the
roof
rafters with correct spacing before the roof panels can be positioned on top
of the
rafters and nailed to the cleats. This can be a time-consuming process.
Therefore, providing a weather-resistant exterior cladding panel for building
construction having raised ribs for structural and decorative purposes that
can be
secured to roof rafters or side wall studs without clips or raised solid wood
cleating
backing strips, and which conceal screw or nail heads from moisture
penetration
would be advantageous. The lateral edges of the panel assembly along a roof or
wall
end should be secured to combat the effects of wind shear. Moreover, the
shanks of
the nails or screws used to secure the panel assembly should be resistant to
wind
shear. Finally, the individual panels should have a profile that allows them
to be
stacked during transport or storage or at a construction site.
Summary of the Invention
An exterior cladding panel assembly for covering an outside surface of a
framed building is provided by the invention. A unique rib and batten system
allows
through fastening of wide panels on the order of 32 inches or greater to the
building's
underlying framing structure with complete concealment of the fasteners. The
panels
arc substantially planar with a female raised major rib along their first
lateral edge, a
supporting male end rib along the opposite lateral edge, and full raised major
ribs
along interior positions therebetween. These female and male edge ribs are
formed
along the panels such that when the female rib of one panel laps over the male
rib of
the other panel to form an interconnected panel assembly, proper panel
alignment is
produced. The lapped ribs of the panels are then attached to the underlying
framing
of the building structure by means of a common nail or screw driven through
the
raised ribs with a space between the rib top surface and the underlying
framing
member, thereby resulting in a shear connection with the associated bracing
properties, thereby enhancing the building's structural integrity.
The ribs are formed with an inverted U-shaped end profile, instead of a W-
shaped end profile found in the prior art, to eliminate two vertical legs and
reduce
materials and manufacturing costs for the panels and make it easier for a
construction
worker to attach them to the building. The ribs are formed with longitudinal
detents
5
CA 02901202 2015-07-22
in each face. A batten cap is snapped into engagement with these longitudinal
detents
along the major rib to cover the nail or screw heads to render the panels
moisture and
weather-resistant.
The overlapping female and male ribs of the through-fastened, fastener-
concealed panels of the present invention produce "stitched edges" in
combination
with the common fastener driven through the lapped ribs to prevent movement
between the panels. These stitched panels transfer shear forces via tension
fields from
one panel to the next panel. It is this force transfer that enables the
stitched panels to
function as the shear transfer element of the diaphragm system, thus
eliminating the
need for sub-sheathing to perform that function. The through-fastened,
fastener-
concealed panels of the present invention also eliminate the need for clips
used in the
prior art systems to attach the panels to the underlying framing members. This
saves
material and labor costs, while enabling more direct, stronger, and rigid
connection
between the panel and the structural framing. Also, the panels of the present
invention are designed, so that they can be installed to the roof without the
need for
solid backing material. This feature saves the materials and labor needed to
install the
filler. The flat region of the panels between the major ribs preferably
includes at least
one inverted minor rib having a substantially flat bottom surface. The bottoms
of the
minor ribs are slightly lower than the exposed flat panels. Thus, the panel
flats do not
make firm contact with the purlins. This minor rib acts to break up the flat
region to
stiffen its material to decrease the natural tendency of the panel to move
towards and
away from the building's underlying framing members to produce undulations in
the
panel's flat regions ("oil canning"). These minor ribs also space the panel a
slight
distance from the framing member to reduce the natural tendency of the panel
to
telegraph ("show") the form of the underlying framing member in its material
("ghosting").
The ribs taper from wide at the bottom to narrow at the top. This taper allows
the panels to nest. Nesting panels simplifies shipping, thereby reducing
transport
costs. Moreover, the panels may be stacked on top of each other during storage
or at
a construction site.
In a preferred embodiment, special nails or screws having an extended shank
with a substantial solid portion of the shank without threads are used to
secure the
6
CA 2901202 2017-03-16
panel assembly to the framing member. By driving the extended shank portion of
the
screw or nail below the framing member surface, wind-induced uplift of the
panel
assembly is reduced while also reducing wind-induced shearing of the screws or
nails
along the outer surface of the framing member.
In a preferred embodiment, a flat region of the panel assembly is secured
directly
to the framing members along the edge of the roof line or wall to thwart the
panel from
moving under the influence of the wind along the framing members of the roof
or wall.
The through-fastened, fastener-concealed panels of the present invention are
used
to form water-shedding roof and wall systems. They can be used anywhere
through-
fastened panels have been traditionally used. The panels can also be used to
replace
water-shedding, standing-seam panels. Furthermore, the panels can replace
other types
of water-shedding finishes, including asphalt shingles, wood shakes, clay
tiles, lap siding,
etc.
The through-fastened, fastener-concealed panels of the present invention are
designed to span open purlins, No structural sheathing is required. Assemblies
that
include the panels have excellent shear strength and stiffness. These
assemblies therefore
can be used as part of the building's lateral load-resisting system.
In accordance with an aspect of the present invention, there is provided a
cladding
panel assembly for attachment to a framing member of a building, the panel
comprising:
(a) a sheet of material having a top surface, a first lateral edge and a
second lateral edge
opposite the first lateral edge; (b) at least one interior rib formed in and
extending
upwardly from the top surface of the sheet of material, the interior rib
having a generally
inverted U-shape including a top wall for receiving a fastener to secure the
interior rib to
a building framing member, a first side wall and a second side wall opposite
the first
wall, the interior rib being positioned at a point along the panel between the
first lateral
edge and the second lateral edge of the panel, the interior rib further having
a first
longitudinal detent formed along the first side wall and a second longitudinal
detent
formed along the second side wall to define a head, neck and body region of
the interior
rib;(c) a female rib formed in and extending upwardly from the top surface of
the sheet of
7
CA 2901202 2017-03-16
material along the first lateral edge of the panel, the female rib having a
generally
inverted U-shape including a top wall, a first side wall and a second side
wall opposite
the first wall, a first longitudinal detent formed along a first side wall of
the female rib
and a second longitudinal detent formed along an opposite second side of the
female rib
to define a head, neck and body section of the female rib; (d) a male rib
formed in and
extending upwardly from the top surface of the sheet of material along the
second lateral
edge of the panel, the male rib having a generally inverted U-shape including
a top wall,
a first side wall and a second side wall opposite the first wall and an end
profile slightly
smaller than an end profile of the female rib, such that the female rib of a
first panel will
nest on top of the male rib of a second underlying panel so the male and
female top walls
are aligned for fasteners to pierce the top walls of the nested female and
male ribs and
their corresponding underlying building framing member; (e) a generally
inverted U-
shape first batten sealing cap adapted to cover the head region of the
interior rib, the first
batten sealing cap having a top wall and two side walls with outer edges, the
first batten
sealing cap being secured to the interior rib by engagement of the side wall
edges with
corresponding first and second longitudinal detents forming the neck of the
interior rib,
such that the top wall of the first batten sealing cap is spaced from the top
wall of the
interior rib to accommodate the space required for the head of the fasteners;
and (f) a
generally inverted U-shape second batten sealing cap adapted to cover the head
region of
the female rib, the second batten sealing cap having a top wall and two side
walls with
outer edges, the second batten sealing cap being secured to the female rib by
engagement
of the side wall edges with corresponding first and second longitudinal
detents in the
female rib, such that the top wall of the second batten sealing cap is spaced
from the top
wall of the female rib to accommodate the space required for the head of the
fasteners.
In accordance with another aspect of the present invention, there is provided
a
method of securing two or more panels to substantially parallel, spaced
framing members
of a building, each panel comprising: (a) a sheet of material having a top
surface, a first
lateral edge and a second lateral edge opposite the first lateral edge; (b) at
least one
interior rib formed in and extending upwardly from the top surface of the
sheet of
material, the interior rib having a generally inverted U-shape including a top
wall for
receiving a fastener to secure the interior rib to a building framing member,
a first side
7a
CA 2901202 2017-03-16
wall and a second side wall opposite the first wall, the interior rib being
positioned at a
point along the panel between the first lateral edge and the second lateral
edge of the
panel, the interior rib further having a first longitudinal detent formed
along the first side
wall and a second longitudinal detent formed along the second side to define a
head, neck
and body region of the interior rib; (c) a female rib formed in and extending
upwardly
from the top surface of the sheet of material along the first lateral edge of
the panel, the
female rib having a generally inverted U-shape including a top wall, a first
side wall and
a second side wall opposite the first wall, a first longitudinal detent formed
along the first
side wall of the female rib and a second longitudinal detent formed along the
second side
of the female rib to define a head, neck and body section of the female rib;
(d) a male rib
formed in and extending upwardly from the top surface of the sheet of material
along the
second lateral edge of the panel, the male rib having a generally inverted U-
shape
including a top wall, a first side wall and a second side wall opposite the
first wall and an
end profile slightly smaller than an end profile of the female rib, such that
the female rib
of a first panel will nest on top of the male rib of a second underlying panel
so the male
and female top walls are aligned for fasteners to pierce the top walls of the
nested female
and male ribs into a building framing member; (e) a generally inverted U-shape
batten
sealing cap adapted to cover the head region of the interior and female ribs,
the batten
sealing cap having a top wall and two side walls with outer edges, the batten
sealing cap
being secured to the interior or female rib by engagement of the side wall
edges with
corresponding first and second longitudinal detents forming the neck of the
interior or
female rib, such that the top wall of the batten sealing cap is spaced from
the top wall of
the interior or female rib to accommodate a space required for the head of the
fasteners,
the method comprising the steps of:
a. placing a first panel on framing members oriented perpendicular to the ribs
of the
first panel, aligning the female rib with an edge of the building area to be
covered;
b. fastening the panel to the framing by driving fasteners through the female
and
interior ribs into each underlying framing member;
7b
CA 2901202 2017-03-16
c. installing batten sealing caps onto the top of the female and interior
ribs of the
first panel;
d. placing a second panel in adjoining relation with the first panel with the
female
rib of the second panel placed over the male rib of the first panel;
e. installing fasteners through the female and interior ribs of the second
panel into
each underlying framing member; and
installing batten sealing caps onto the top of the female and interior ribs of
the second
panel.
In accordance with another aspect of the present invention, there is provided
a
cladding panel assembly for attachment to a framing member of a building, the
cladding
panel comprising: (a) a sheet of material having a top surface, a first
lateral edge and a
second lateral edge opposite the first lateral edge; (b) at least one interior
rib formed in
and extending upwardly from the top surface of the sheet of material, the
interior rib
having a generally inverted U-shape including a top wall for receiving a
fastener to
secure the interior rib to a building framing member, a first side wall and a
second side
wall opposite the first side wall, the interior rib being positioned at a
point along the
cladding panel between the first lateral edge and the second lateral edge of
the cladding
panel, the interior rib further having a first longitudinal detent formed
along the first side
wall and a second longitudinal detent formed along the second side wall to
define a head,
neck and body region of the interior rib; (c) a female rib formed in and
extending
upwardly from the top surface of the sheet of material along the first lateral
edge of the
cladding panel, the female rib having a generally inverted U-shape including a
top wall, a
first side wall and a second side wall opposite the first side wall, a first
longitudinal
detent formed along a first side wall of the female rib and a second
longitudinal detent
formed along an opposite second side of the female rib to define a head, neck
and body
section of the female rib; (d) a male rib formed in and extending upwardly
from the top
surface of the sheet of material along the second lateral edge of the cladding
panel, the
male rib having a generally inverted U-shape including a top wall, a first
side wall and a
second side wall opposite the first side wall and an end profile smaller than
an end profile
7c
CA 2901202 2017-03-16
of the female rib, such that the female rib of a first panel will nest on top
of the male rib
of a second underlying panel so the male and female top walls are aligned for
fasteners to
pierce the top walls of the nested female and male ribs and their
corresponding
underlying building framing member; (e) a generally inverted U-shape first
batten sealing
cap adapted to cover the head region of the interior rib, the first batten
sealing cap having
a top wall and two side walls with outer edges, the first batten sealing cap
being secured
to the interior rib by engagement of the side wall edges with corresponding
first and
second longitudinal detents forming the neck of the interior rib, such that
the top wall of
the first batten sealing cap is spaced from the top wall of the interior rib
to accommodate
the space required for the head of the fasteners; and (f) a generally inverted
U-shape
second batten sealing cap adapted to cover the head region of the female rib,
the second
batten sealing cap having a top wall and two side walls with outer edges, the
second
batten sealing cap being secured to the female rib by engagement of the side
wall edges
with corresponding first and second longitudinal detents in the female rib,
such that the
top wall of the second batten sealing cap is spaced from the top wall of the
female rib to
accommodate the space required for the head of the fasteners.
In accordance with another aspect of the present invention, there is provided
a
method of securing two or more panels to substantially parallel, spaced
framing members
of a building, each panel comprising: (a) a sheet of material having a top
surface, a first
lateral edge and a second lateral edge opposite the first lateral edge; (b) at
least one
interior rib formed in and extending upwardly from the top surface of the
sheet of
material, the interior rib having a generally inverted U-shape including a top
wall for
receiving a fastener to secure the interior rib to a building framing member,
a first side
wall and a second side wall opposite the first side wall, the interior rib
being positioned
at a point along the panel between the first lateral edge and the second
lateral edge of the
panel, the interior rib further having a first longitudinal detent formed
along the first side
wall and a second longitudinal detent formed along the second side to define a
head, neck
and body region of the interior rib; (c) a female rib formed in and extending
upwardly
from the top surface of the sheet of material along the first lateral edge of
the panel, the
female rib having a generally inverted U-shape including a top wall, a first
side wall and
a second side wall opposite the first side wall, a first longitudinal detent
formed along the
7d
CA 2901202 2017-03-16
first side wall of the female rib and a second longitudinal detent formed
along the second
side of the female rib to define a head, neck and body section of the female
rib; (d) a male
rib formed in and extending upwardly from the top surface of the sheet of
material along
the second lateral edge of the panel, the male rib having a generally inverted
U-shape
including a top wall, a first side wall and a second side wall opposite the
first side wall
and an end profile smaller than an end profile of the female rib, such that
the female rib
of a first panel will nest on top of the male rib of a second underlying panel
so the male
and female top walls are aligned for fasteners to pierce the top walls of the
nested female
and male ribs into a building framing member; (e) a generally inverted U-shape
batten
sealing cap adapted to cover the head region of the interior and female ribs,
the batten
sealing cap having a top wall and two side walls with outer edges, the batten
sealing cap
being secured to the interior or female rib by engagement of the side wall
edges with
corresponding first and second longitudinal detents forming the neck of the
interior or
female rib, such that the top wall of the batten sealing cap is spaced from
the top wall of
the interior or female rib to accommodate a space required for the head of the
fasteners,
the method comprising the steps of:
a. placing a first panel on framing members oriented perpendicular to the
ribs of the
first panel, aligning the female rib with an edge of the building area to be
covered;
b. fastening the panel to the framing by driving fasteners through the
female and
interior ribs into each underlying framing member;
c. installing batten sealing caps onto the top of the female and interior
ribs of the
first panel;
d. placing a second panel in adjoining relation with the first panel with
the female
rib of the second panel placed over the male rib of the first panel;
e. installing fasteners through the female and interior ribs of the second
panel into
each underlying framing member; and
f. installing batten sealing caps onto the top of the female and
interior ribs of the
second panel.
7e
CA 2901202 2017-03-16
Brief Description of the Drawings
In the accompanying drawings:
Figure 1 is a perspective view of a building under construction with part of
the
roof covered by the exterior cladding panel assembly of the present invention.
Figure 2 is a perspective view of a portion of the exterior cladding panel of
the
present invention.
Figure 3 is an enlarged end view of an overlapping joint between the edges of
two
adjacent panels without the batten cap cover of Fig. 4.
Figure 4 is a perspective view of a batten cap cover of the present invention.
7f
CA 02901202 2015-07-22
Figure 5 is an edge view of a exterior cladding panel assembly secured to an
underlying purlin with the batten cap covers secured to two of the raised
ribs, and the
batten cap cover removed from a third rib in exploded format.
Figure 6 is a cut-away view of the exterior cladding panel secured to the
underlying purlin by an extended-shank screw, and with the batten cap cover
secured
to the raised rib.
Figure 7 is a perspective view of a portion of a prior art panel product
secured
to an underlying framing member.
Figure 8 is an end view of an exterior cladding panel of the present invention
secured to the edge of a building roof line with extra securement means for
preventing
panel migration along the purlins, and with a gable flashing secured to the
panel's
edge.
Detailed Description of the Preferred Embodiment
The roof industry has for decades searched for a panel that has the weathering
and appearance characteristics of current standing-seam panels, and the
bracing and
diaphragm capacity inherent with through-fastened, concealed fastener panels.
An
exterior cladding panel assembly for covering an outside surface of a framed
building
is provided by the invention. A unique rib and batten system with overlapping
raised
female and male edge ribs on the adjacent installed panels, and raised
interior ribs
allow through fastening of the panels on the order of 32 inches or wider to
the
building's underlying framing structure with complete concealment of the
fasteners,
and without the need for special fastener clips. The ribs have an inverted U-
shaped
end profile that creates an open cavity between the rib top wall and the
underlying
framing member. The fastener can be driven through the rib top walls into the
framing member without the need for a solid filler cleating strip. The lapping
female
and male ribs also force proper alignment of the panels with each other during
installation. Special inverted ribs extending downwardly from the panel
offsetting the
flat panel surfaces from the framing members to minimize the formation of
undulations in the panel's flat region ("oil canning") and the formation of
the framing
member's shape over time in the panel ("ghosting"). Tapered side walls on the
raised
and inverted ribs allow the panels to nest one on top of another during
transport,
storage, or at the construction site.
8
CA 02901202 2015-07-22
In the context of the present application, "exterior cladding panel" means a
substantially planar piece of structural component that is positively
connected to the
framing structure of a building to strengthen the framing structure and
achieve shear
value, while providing weather-resistant protection to the building interior.
Such
exterior cladding panel include raised ribs interposed along the otherwise
planar
profile. The ribs provide structural integrity and a pleasing aesthetic. The
panels may
be used to cover a portion of the building such as a roof or wall.
For purposes of the present invention, "building" means any usually roofed
and walled structure built for permanent use, including, without limitation, a
house;
apartment; pole barn; farm or ranch building like a machine shed or shop, cold
storage, heated farm shop, agricultural building, or grain storage; livestock
building
like livestock housing, dairy building or milking parlor, hog nursery, hay or
grain
storage, or offices; equestrian building like a horse barn, stalls, stables,
riding arena,
or tack room; hobby building like a garage, storage shed, or work shop; or
commercial building like an office, retail store, restaurant, event center,
municipal
building, self-storage building, mini-storage building, church, or warehouse.
As used within this Application, "framing member" means any wood or metal
member that is interconnected to other members to provide the framing
structure
underneath the exterior cladding for a building, such as rafters, purlins,
studs, header
plates, or footer plates.
While the exterior cladding panel assembly of the present invention is
disclosed for purposes of this Application as a roof for a building, it should
be
understood that the exterior cladding panel assembly may be used to cover a
different
portion of a building frame, such as a wall. It should also be understood that
the
panels may be used to cover an interior ceiling or wall of the building where
weather
resistance is not necessarily required. Such interior application of the
panels will help
to brace and strengthen the building's framing structure, while providing an
aesthetically pleasing design element.
The exterior cladding panel assembly 10 of the present invention is shown in
Fig. I in partially cut-away view. A building 12 has a structure defined by a
plurality
of framing members 14 connected to each other. More specifically, the four
walls 15
9
CA 02901202 2015-07-22
of the building (two shown) are defined by a plurality of vertical studs 16
that are
connected at their bottom ends to footer plate 18, and at their top ends to
header plate
20. Extra studs 22 along with footer plate 24 and header plate 26 define
window
openings 27. Similarly, extra studs 28 and header plate 30 define door opening
32.
Meanwhile, the roof 36 of the building 12 is defined by a series of rafters 38
and a ridge purlin 40. The rafters 38 may entail individual boards, or else
the top
members of preassembled trusses 42 that comprise interconnected rafter boards
44,
bottom plate 46, and a plurality of angled support members 48 for
strengthening the
truss and displacing the load carried by the roof. The rafters or top rafter
elements of
the trusses 42 are sloped to define the pitch of the roofline. Finally, a
series of purlin
members 50 are attached between the rafters or rafter elements of the trusses
to
provide lateral stability and maintain the vertical alignment of the rafters
or trusses.
These purlins 50 also provide attachment surfaces 52 along their top surfaces
along
with the attachment surfaces of the rafters or trusses for securement of the
exterior
cladding panels 60, as described below.
The exterior cladding panels 60 are secured to the roof of building 12 by
means of fasteners 62 with adjacent panels attached to each other to form
exterior
cladding panel assembly 64. The panel 60, as shown more clearly in Fig. 2, has
a
nominal width W of 32 inches, which is measured from the centers of female end
rib
66 and supporting male end rib 68. Typically, the panel can be manufactured to
a
length L of 40 feet or longer. These dimensions are typical for the exterior
cladding
panel 60 of the present invention, and not meant to limit it in any manner.
The panel 60 comprises female end rib 66 along its one edge 70. This female
end rib 66 is formed from tapered side wall 72 extending upwardly from
horizontal
panel wall 102, top wall 74 with longitudinal crease 75 formed therein, and
side wall
76 which extends partially downwardly towards the panel wall 102 and
substantially
planar surface 78 of panel 60 without touching it. Formed along side walls 72
and 76
near top wall 74 are the detent grooves 80 which run the length of the panel.
Supporting male end rib 68 is formed along edge 82 of panel 60, which is the
opposite edge of edge 70. This supporting male end rib 68 is formed with first
tapered side walls 84, second tapered side walls 86 having a slope greater
than the
CA 02901202 2015-07-22
slope of first tapered side walls 84, and top wall 88. Supporting male end rib
68 does
not include any detent grooves.
Panel 60 also includes at least one interior upright rib 90 formed along panel
60 between female end rib 66 and supporting male end rib 68. If there is only
one
interior upright rib 90 ion panel 60, it will be formed along the center of
the panel. If
there are multiple interior upright ribs 90, they will be formed along the
panel so that
the spacing distance D between female end rib 66 and interior upright rib 90,
between
two interior upright ribs 90, and between interior upright rib 90 and
supporting male
end rib 68 are substantially equal. Interior upright rib 90 is formed from two
complete tapered side walls 92 and top wall 94, and features a pair of detent
grooves
96 near the top wall. The end profile for interior upright rib 90 and female
end rib 66
should be substantially similar in terms of the width of top walls 94 and 66,
lengths
and slopes of side walls 92 and 72, and the positioning of longitudinal detent
grooves
96 and 80 so that the two ribs will look substantially similar for aesthetic
purposes for
the panel.
Also extending along panel 60 are a plurality of inverted "minor" ribs 100.
These ribs 100 have substantially flat bottom walls 102 flanked by tapered
side walls
104. The width X1 of flat bottoms walls 102 should be substantially less than
the
width X, of the panel regions 78 between adjacent inverted ribs 100.
Referring now to Fig 3, an enlarged end view of the overlapping joint between
the edges of a pair of adjacent panels 60a and 60b is shown. The female end
rib 66 of
panel 60b is placed over the supporting male end rib 68 of panel 60a. The
shape and
dimensions of the female end rib 66 and supporting male end rib 68 should be
such
that side wall 72 of female end rib 66 abuts against side wall 84 of
supporting male
end rib 68; side wall 80 of female end rib 66 abuts against side wall 84 of
supporting
male end rib 68; and top wall 66 of female end rib 66 abuts against top wall
88 of
supporting male end rib 68. Note that tapered side wall 76 of female rib on
panel 60b
does not need to touch wall portion 102 of panel 60a, because it is supported
by the
top of the male rib and therefore is not purlin-bearing. At the same time,
tapered side
wall 84b on the male rib of panel 60a does extend down to and touch the
purlin,
because it is a purlin-bearing leg of the panel, which provides firm support
to the
lapping female-male rib combination.
11
CA 02901202 2015-07-22
Moreover, the lapped female-male ribs of the two panels force proper
alignment of the two panels 60 with each other producing the panel assembly
64. The
overlapeed ribs along the panel lengths provide a ready means for preventing
one
panel from becoming cocked with respect to the other panel during
installation.
Because female end rib 66 covers supporting end rib 68, this rib assembly will
provide the same visual appearance as interior upright ribs 90 formed on
panels 60a
and 60b to enhance the aesthetic appearance of the panel assembly 64.
Moreover, the
rib assembly will enhance the strength of the panel and provide means of
attaching the
panel at intermediate locations.
Rain water and moisture may tend to collect in the well formed by minor
inverted rib 100 (see Fig. 3). This water may tend to get wicked up between
female
rib side wall 76 and male rib side wall 84a, since very tight clearances
between the
two side walls makes the water cling through capillary action. If left
unconstrained,
this water can travel upwards along the left side walls gap, through the gap
between
the rib top walls 70 and 88, and then downwards along the gap between the
right
sidewalls 72 and 84b of the lapped female and male ribs. However, the panel 60
of
the present invention is designed with a void space 83 in the upper left
corner between
the lapped ribs to collect this migrating water and break the capillary
action. A
backup void 85 is formed in the upper right corner of the lapped ribs. These
voids
should be 1/8 inch wide or greater. The shortened leading side wall 76 of the
female
rib 66 will also serve to raise the gap entry point between the female and
male ribs
above inverted rib well 100, and therefore make it more difficult for the
collected
water to be drawn via capillary action into the gap between the rib walls.
The major ribs 90, 66 extending vertically from the substantially planar
surface of panel 60 should preferably be about 1-2 inches wide across its
base, more
preferably about 1-1/4 inch, with a shorter width across the top wall due to
the tapered
side walls. Such top wall dimension is preferably about about 1 inch wide. The
major ribs 90, 66 should also preferably be about 1-2 inches tall, more
preferably
about 1-1/4 inch tall, or about 1-1/2 inches tall with the batten cap
installed. The side
walls of the rib should be tapered, preferably with an about 10-30 slope.
These
sloped side walls make it easier to assemble the partial end rib 66 on top of
the
12
CA 02901202 2015-07-22
supporting end rib 68. The sloped side walls of the ribs also make it easier
to stack
panels on top of each other during transport, storage, or use at a
construction site.
The panels 60 may be fabricated from sheet metal material such as galvanized
steel that may optionally be pre-painted prior to manufacture. The galvanized
coating
may consist of zinc or aluminum/zinc, or zinc/manganese/aluminum mixtures.
Alternatively, the panels may be fabricated from aluminum, which is lighter
than
galvanized steel and does not rust, but is also generally more expensive than
galvanized steel. Copper is another material that may be used for the panels
of the
present invention, particularly for specialty applications. Any other type of
metal or
metal alloy may be used, provided that it can be roll formed to produce the
necessary
end profile for the panel. Alternatively, panels 60 may be fabricated from a
plastic
material, such as an acrylic resin with a fiberglass reinforcing material, or
polycarbonate. While plastic may not hold the form for structural details as
well as
metal, it may still be suitable for panel applications that do not require
such intricate
details.
Batten cap 110 is shown in perspective view in Fig. 4. The cap is typically
fabricated out of the same material as panel 60, although other alternative
materials
may be used. Batten cap 110 should be produced with the same length L as the
length
L of the panel 60 to which they will be secured.
The batten caps 110 are formed in substantially inverted U-shaped troughs
with a flat, planar upper surface 112. However, upper surface 112 may
alternatively
be curvilinear or any other geometrical shape, if so desired. While the batten
caps
110 are used to cover the ribs and the fasteners that penetrate the ribs to
secure them
to the roof purlins, as described below, they also provide an ornamental
feature to the
roof panel design.
The sides 114 and 116 extend downwardly from the upper surface 112 of
batten cap 110. In a preferred embodiment, sides 114 and 116 are formed at an
angle
relative to the upper surface 112 in order to conform to and securely engage
with the
tapered side walls 76 and 72 of female end rib 66 which has been placed over
supporting male end rib 68, as well as tapered side walls 92 of intermediate
upright
ribs 90.
1.3
CA 02901202 2015-07-22
The sides 114 and 116 of batten cap 110 include elongated folds or lips 118
and 180 formed along the interior surface of the side walls. While these
elongated
lips 118 and 180 are preferably located near the distal ends of the side walls
114 and
116, they can be formed along an interior position along the side walls, as
long as the
lips 118 and 180 can engage the detent grooves 80 and 96 in ribs 70 and 90,
respectively, as discussed more fully below.
Referring now to Fig. 5, an edge view of the three panels 60a, 60b and 60c
assembled together and secured by means of fasteners 120(120a, 120b, 120c) to
purlins 50 of the framing structure for the building's roof is shown. As shown
more
clearly in the drawing, panel 60 has female end rib 66, interior upright rib
90, and
supporting male end rib 68 formed along its surface. Female end rib 66 of
panel 60b
fits over and around supporting male end rib 68 of panel 60a. Similarly,
female end
rib 66 of panel 60a fits over and around supporting male end rib 68 of panel
60c.
Fastener 120a is driven through the top wall 94 of interior upright rib 90 and
penetrates into the purlin 50 to secure the middle region of panel 60a to the
purlin and
its associated roof framing. Fastener 120b is driven through the top wall 74
of female
end rib 66 of panel 60b and the top wall 88 of supporting male end rib 68 of
panel 60b
below it, and penetrates into purlin 50. This common fastener secures panels
60b and
60a in their interconnected state to the purlin and its associated roof
framing.
Meanwhile, fastener 120c is driven through the top wall 74 of female end rib
66 of
panel 60a and top wall 88 of supporting male end rib 68 of panel 60c below it,
and
likewise penetrates into purlin 50. This common fastener 120c secures panels
60a and
60c in their interconnected state to the purlin and its associated roof
framing.
Longitudinal creases 75 and 99 may be formed within the top walls 74 and 98 of
the
female rib 66 and interior rib 90, respectively, to assist a construction
worker to
properly position the fasteners 120(120a, 120b, 120c) to drive them through
the rib
top walls into the purlins below.
In order to prevent rain and other moisture from penetrating through the
region
of panel 60a pierced by fastener 120a, batten cap 110 is placed over the top
of
intermediate upright rib 90 with its elongated lips 118 and 180 snapped into
engagement with longitudinal detent grooves 96 formed into side wall 92 of the
rib.
This batten cap 110 completely covers fastener heads 120h. At the same time,
the
14
CA 02901202 2015-07-22
batten cap 110 will also conceal the fastener heads to improve the aesthetic
appearance of the panel 60a when it is secured to the roof Similar batten caps
110
cover and conceal the respective fasteners 120b driven into the interconnected
panel
60b female end rib 66/panel 60a supporting male end rib 68, and fasteners 120c
driven into the interconnected panel 60a female end rib 66/panel 60c
supporting male
end rib 68. With these batten caps 110, the major ribs formed along the panel
assembly 64 will appear identical for aesthetic purposes.
Fasteners 120(120a, 120b, 120c) may constitute nails or screws. Screws are
preferred because their helical flights impede the loosening of the screws
from the
purlins 50 when a force, such as a strong wind, is applied to the panels 60 on
the roof
top. However, nails with rings along their shank will bite into the wood
material of
the purlin, therefore holding the panels securely to the purlins. The
fasteners
120(120a, 120b, 120c) should be fabricated from a suitable material that is
strong and
rust-resistant. Galvanized steel and stainless steel are two appropriate
materials,
although other materials are available. A suitable sealant or grommet ring may
be
placed on each screw or nail head before placement of the batten cap 110 to
enhance
water leakage resistance.
A preferred embodiment of fastener 130 is shown in Fig. 6. It constitutes an
elongated-shank screw having a head 132, shank 134, and helical flight
threaded
portion 136. For a #12 or #14 screw that is 2-1/2 or 3 inches in length, the
threaded
portion of the screw should cover at least approximately 1 inch from the tip
end of the
screw to provide sufficient bite in the wood purlin 50 to inhibit
disengagement of the
screw from the pulrin under, e.g., windy conditions. At the same time, shank
portion
134 of the screw 130 should be sufficiently long, so that at least 1/4 inch of
the shank
extends below the purlin surface when the screw is driven into the purlin to
secure the
panel 60 in place. Because the diameter of the shank region 134 is greater
than the
diameter of the threaded region 132 and does not contain reduced material
around the
screw flights, this extended-shank screw 130 will be less likely to break off
along the
top surface of the purlin 50 under, e.g., wind shear. The use of these
extended-shank
screws 130 will help to secure the panels 60 to the roof under windy
conditions.
Unlike panel assemblies of the prior art, the exterior cladding panel assembly
64 of the present invention provides several advantages. First, interior
upright rib 90
CA 02901202 2015-07-22
and female end rib 66 contain an inverted-U end profile characterized in
general by
two side walls and a top wall. This is different from the W-shaped end profile
configuration of the upright rib structure of, e.g., U.S. Patent No. 7,104,020
shown in
Fig. 7 where the "rib" 140 actually consists of a left-hand rib 142 and right-
hand rib
144 in combination. Such a prior art structure requires additional material
along the
left-hand rib inner side wall 146 and right-hand rib inner side wall 148, as
well as
additional folding of the material during the manufacturing operation to
produce such
a double-ribbed, W-shaped end profile. The inverted U-shaped profile of the
exterior
cladding panel 60 of the present invention improves the economics of panel
manufacture by more than fifteen percent reduced materials costs and
significantly
reduced capital equipment, packaging, and transport costs. Thus, the panel
design of
the present invention provides the full package of physical features and
economies
required for a commercially viable product.
Second, unlike the W-shaped end profile of the prior art roofing panel in
which the screw 150 is driven into a trough portion 152 of the rib profile
directly
against the roof framing member, the fastener 130 for the exterior cladding
panel
system of the present invention is driven into the tops of the ribs 90, 68
which do not
directly abut against the purlin 50 or other roof framing member. Instead an
open
space exists between the rib top of the U-shaped end profile and the purlin.
It is easier
for a construction worker to drive a fastener 130 into the top surfaces of the
upright
ribs, instead of down into the trough 152 between left-hand rib 142 and right-
hand rib
144 as is required for the prior art system (See Fig. 7). At the same time,
Applicants
have discovered to their surprise that this U-shaped rib end profile where the
panel 60
does not directly abut against the purlin at the point of screw connection
still provides
superior attachment of the panels to the purlins even under windy conditions
that can
produce forces that could otherwise lift the panels vertically off the roof
framing
members, or shift them laterally or longitudinally along the roof line. At the
same
time, there is no need under the exterior cladding panel system of the present
invention to use wood fill cleating strips prepositioned on the purlins to
fill up the
open space inside the U-shaped rib with solid backing material, and to provide
an
abutment surface against which the top surface of the U-shaped rib can be
directly
secured. Dispensing with these cleating strips saves significant time and
materials
costs during the installation of the roofing panels to the roof.
16
CA 02901202 2015-07-22
Figure 8 shows a preferred embodiment of the exterior cladding panel system
of the present invention with a focus upon the lateral edge of the roofing
panel
assembly 64. Purlin 50 is attached to truss 42, which in turn rests on top of
wall stud
or header plate 164. Facia board 166 is secured to the lateral end of the
purlin/truss
assembly to define the lateral edge of the roof line. Exterior cladding panel
60 is
positioned against the top of the surfaces of purlin 50, truss 42, and facia
board 166 so
that supporting male end rib 68 hangs slightly beyond the facia board 166.
Extended-
shank screws 130 penetrate the top wall 94 of interior upright rib 90 to
secure it in
place along the purlins 50 with the open space between the rib top and purlin,
as
described above. Meanwhile fasteners like screws 170 are driven through the
flat
regions 172 of panel 60 and the inverted rib 174 to secure the panel in direct
abutted
relationship against the purlin 50 and facia board 166. Gable flashing 176 may
then
be used to cover the edge of panel 60, including supporting end rib 68 and
secured to
the room in direct abutted relationship by means of screws 170 and 178. Not
only
does gable flashing 176 act to prevent wind shear from lifting up the lateral
edge of
panel 60 from the roof line, but also it provides an aesthetically pleasing
decorative
covering around the edge of the roofing panel assembling. Moreover, screws 170
will
prevent lateral movement of panel 60 along the roof top under the influence of
the
wind
In an important feature of the exterior cladding panel system of the present
invention, panels 60 include a plurality of inverted "minor" ribs 100 (see
Fig. 2).
These minor ribs are positioned along the flat region of the panel between the
upright
major ribs 90, 68. The minor ribs 100 run parallel to the major upright ribs.
They
feature a substantially flat bottom surface 102 with tapered side walls 104.
Thus, the
flat bottom surfaces 102 rest upon the purlins 50, and enable the broader flat
regions
78 of the panel to be elevated a small distance above the purlins. If the flat
panel
regions 78 rested directly on top of the purlins, then the panel 60 would tend
to hump
up and hump down over the purlin over time due to changing temperatures and
building movements to impart stresses on the panel's flat panel regions. This
natural
process called "oil canning" would add unwanted undulations to the panel 60
which
would ruin the decorative appearance of the roof panel. The inverted minor
ribs 100
act to stiffen the panel to minimize these puckered undulations, and to break
up the
stress fields to make any puckering less noticeable. The slight elevation of
the panel's
17
CA 02901202 2015-07-22
flat pan regions 78 above the purlins 50 also acts to reduce any formation of
the
purlin's profile into the panel over time ("ghosting"). Because the .width of
the
bottom surface 102 of the minor inverted ribs 100 is substantially less than
the width
of the flat panel regions 78, most of the panel 60 will lie spaced above the
purlins.
These minor inverted ribs 100 should preferably be about 1/4 to 1 inch wide,
preferably
1/2 inches wide across the flat bottom 102. The minor inverted ribs 100 should
also
preferably be about about 1/8 to 3/16 inches tall, measured between their flat
bottom
and flat planar region 78 of the panel 60.
The exterior cladding panels 60 of the present invention should be fabricated
from light-weight 29 to 22 gauge (i.e., 0.015 to 0.03 inches) thickness metal
coil. The
metal material is roll formed at the point of manufacture, whereby the coil of
flat
metal is uncoiled and passed through a series of interlocking rolls which
progressively
bend the material to produce the interior upright ribs 90, female end rib 66,
supporting
male end rib 68, minor inverted ribs 100, and other structural features of the
final
shape of the panel. This roll forming process for light-gauge metal material
is well-
known in the art. If plastic material is used instead for the panels, then an
extrusion or
mold casting process should be used in order to provide the necessary
structural
features for the ribs.
The above specification and drawings provide a complete description of the
exterior cladding panel system 10 of the present invention. Since many
embodiments
of the invention can be made without departing from the spirit and scope of
the
invention, the invention resides in the claims hereinafter appended.
18
