Note: Descriptions are shown in the official language in which they were submitted.
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MODULAR CLADDING PANELS FOR BUILDINGS AND ASSOCIATED
METHODS
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent
Application Serial No. 63/112,965, which was filed on November 12, 2020,
the disclosure of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The subject matter disclosed herein relates generally
to the
construction of modular construction units. In particular, the presently
disclosed subject matter relates to a connector system for constructing a
building by assembling a plurality of modular units to rigidly interconnect
the
modular units to resist separation forces in the vertical and/or lateral
directions, as well as associated methods of manufacture thereof.
BACKGROUND
[0003] In the field of modular construction, buildings are
constructed from
a plurality of pre-fabricated modular building units assembled together
according to a plan of assembly for the final structure of the building. Such
modular building units can include, for example, one or more rooms within
the building. Such modular building units are pre-fabricated at a location
(e.g., a factory) away from the site where the building (e.g., any suitable
structure, including a temporary or permanent structure) is being
constructed, transported to the building site, and assembled per the
specifications of the building being constructed. In order to ensure that the
structure is sufficiently watertight, it is often necessary to affix an
exterior
cladding, which can be both decorative and functional, over the exposed
surface of the modular units that are on an outer surface of the building
after
the modular units are assembled together during construction of the building.
However, it is also required during assembly of the building being
constructed to precisely align adjacent modular units and to attach the
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modular units rigidly together. Some modular units that are designated as
being on an external surface of the building being constructed may have
exterior cladding panels already affixed thereto during pre-fabrication of the
building units. However, this pre-affixing of cladding panels is still
disadvantageous in that there will inevitably be seams present between
cladding panels of adjacent modular units that must be filled or otherwise
hidden. Additionally, such pre-affixed cladding panels are much more likely
to be cosmetically and/or structurally damaged during transport of the
modular units and/or during assembly of the building being constructed. To
the contrary, however, damage to an external surface of a modular unit to
which a cladding panel is not affixed will likely not need to be remediated,
unless structural in nature, because such damage would be hidden from
view after the cladding panel(s) have been affixed to the modular unit. As
such, a need exists for a suitable cladding panel for covering the exterior of
a
modular unit that can be precisely aligned to ensure fast and repeatable
positioning and fastening of the cladding panel to the external surface of the
modular unit, or units, and which is capable of providing a suitable weather-
resistant barrier to prevent wind and/or water intrusion within the building
after all of the modular units have been assembled together per the
schematics of the building.
SUMMARY
[0004] According to an example aspect, a cladding panel for
covering an
external surface of a building is provided, the cladding panel comprising: a
structural frame; a substrate attached to a first, external, surface of the
structural frame; and a plurality of fasteners that are formed on a second,
internal, surface of the structural frame, the plurality of fasteners being
arranged according to a predetermined pattern. Each of the plurality of
fasteners is configured for attachment to a corresponding one of a plurality
of
cladding alignment features attached on the external surface of the building.
The plurality of cladding alignment features are arranged on the external
surface of the building according to the predetermined pattern, such that
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each of the plurality of fasteners is configured for alignment with, and
attachment to, one of the plurality of cladding alignment features.
[0005] In some
embodiments, the cladding panel comprises one or more
openings formed entirely through a thickness of the substrate, each of the
one or more openings corresponding to an opening formed in the external
surface of the building.
[0006] In some
embodiments, the cladding panel comprises a siding
material attached to a surface of the substrate that is opposite a surface of
the substrate by which the substrate is attached to the structural frame.
[0007] In some embodiments of the cladding panel, each of the plurality
of fasteners comprises a tapered slot; each of the plurality of cladding
alignment features comprises an alignment peg; each alignment peg
comprises a collar and a head attached to an end of the collar, the head
having a width that is greater than a width of the collar; and the width of
the
head is greater than a width of a narrow end of the tapered slot.
[0008] In some
embodiments of the cladding panel, each of the plurality
of fasteners comprises a tapered slot; each of the plurality of cladding
alignment features comprises an alignment peg; each alignment peg
comprises a collar and a head attached to an end of the collar, the head
having a width that is greater than a width of the collar; the width of the
head
is greater than a width of a narrow end of the tapered slot; and each tapered
slot is oriented such that, when the cladding panel is affixed to the
building,
the alignment peg is moved into the narrow end of the tapered slot and held
in place by a gravitational force.
25 [0009] In some
embodiments of the cladding panel, the substrate
comprises a waterproof finish panel.
[0010] In some
embodiments, the cladding panel comprises a gap
between the substrate and the external surface of the building when the
cladding panel is installed on the exterior surface of the building.
30 [0011] In some
embodiments, the cladding panel comprises a gap
between the substrate and the external surface of the building when the
cladding panel is installed on the exterior surface of the building; the gap
is
filled, either partially or entirely, with a rigid insulation layer.
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[0012] In some embodiments of the cladding panel, the
plurality of
fasteners are formed in the second surface of the structural frame in a
unitary manner.
[0013] According to another example aspect, a system for
covering an
external surface of a building is provided, the system comprising: a plurality
of cladding alignment features attached to the external surface of the
building according to a predetermined pattern; and a plurality of cladding
panels. Each of the plurality of cladding panels comprises: a structural
frame; a substrate attached to a first, external, surface of the structural
frame; and a plurality of fasteners that are formed on a second, internal,
surface of the structural frame, the plurality of fasteners being arranged
according to the predetermined pattern, such that each of the plurality of
fasteners is configured for alignment with one of the plurality of cladding
alignment features. Each of the plurality of fasteners is configured for
attachment to a corresponding one of the plurality of cladding alignment
features. Each of the plurality of cladding panels is configured for affixing
to
one or more of the modular units.
[0014] In some embodiments of the system, one or more of
the cladding
panels has a width of at least two of the plurality of modular units that are
laterally adjacent to each other.
[0015] In some embodiments of the system, the building
comprises a
plurality of modular units assembled together to form the building.
[0016] In some embodiments of the system, the building
comprises a
plurality of modular units assembled together to form the building and the
system comprises a plurality of connectors affixed to exterior surfaces of
each of the plurality of modular units, wherein the plurality of cladding
alignment features are rigidly attached to and extend from the connectors for
engagement with the fasteners, and wherein adjacent ones of the plurality of
connectors interlock with each other to secure adjacent ones of the plurality
of modular units together.
[0017] In some embodiments of the system, one or more of
the plurality
of cladding panels comprises one or more openings formed entirely through
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a thickness of the substrate thereof, each of the one or more openings
corresponding to an opening formed in the external surface of the building.
[0018] In some embodiments of the system, each of the
plurality of
cladding panels comprises a siding material attached to a surface of the
substrate that is opposite a surface of the substrate by which the substrate
is
attached to the structural frame.
[0019] In some embodiments of the system, for one or more
of the
plurality of cladding panels, each of the plurality of fasteners comprises a
tapered slot; each of the plurality of cladding alignment features comprises
an alignment peg; each alignment peg comprises a collar and a head
attached to an end of the collar, the head having a width that is greater than
a width of the collar; and the width of the head is greater than a width of a
narrow end of the tapered slot.
[0020] In some embodiments of the system, for one or more
of the
plurality of cladding panels, each of the plurality of fasteners comprises a
tapered slot; each of the plurality of cladding alignment features comprises
an alignment peg; each alignment peg comprises a collar and a head
attached to an end of the collar, the head having a width that is greater than
a width of the collar; the width of the head is greater than a width of a
narrow
end of the tapered slot; and each tapered slot is oriented such that, when
one of the plurality of cladding panels is affixed to the external surface of
the
building, the alignment peg is moved into the narrow end of the tapered slot
and held in place by a gravitational force.
[0021] In some embodiments of the system, the substrate
comprises a
waterproof finish panel.
[0022] In some embodiments of the system, each of the
plurality of
cladding panels comprises a gap between the substrate and the external
surface of the building when the cladding panel is installed on the exterior
surface of the building.
[0023] In some embodiments of the system, each of the plurality of
cladding panels comprises a gap between the substrate and the external
surface of the building when the cladding panel is installed on the exterior
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surface of the building; the gap is filled, either partially or entirely, with
a rigid
insulation layer.
[0024] In some embodiments of the system, the plurality of
fasteners are
integrally formed in the second surface of the structural frame.
[0025] According to another aspect, a method of covering an external
surface of a building is provided, the method comprising: producing a
plurality of cladding panels, each of the plurality of cladding panels
comprising: a structural frame; a substrate attached to a first, external,
surface of the structural frame; and a plurality of fasteners that are formed
on
a second, internal, surface of the structural frame, the plurality of
fasteners
being arranged according to a predetermined pattern; arranging a plurality of
cladding alignment features on the external surface of the building according
to the predetermined pattern; aligning each of the plurality of fasteners with
a corresponding one of the plurality of cladding alignment features on the
external surface of the building; and attaching each of the plurality of
fasteners to the corresponding one of the plurality of cladding alignment
features.
[0026] In some embodiments of the method, producing the
plurality of
cladding panels comprises, for one or more of the plurality of cladding
panels, forming one or more openings through an entire thickness of the
substrate, each of the one or more openings corresponding to an opening
formed in the external surface of the building.
[0027] In some embodiments of the method, producing the
plurality of
cladding panels comprises, for one or more of the plurality of cladding
panels, forming one or more openings through an entire thickness of the
substrate, each of the one or more openings corresponding to an opening
formed in the external surface of the building, the method further comprising
attaching a siding material to a surface of the substrate that is opposite a
surface of the substrate by which the substrate is attached to the structural
frame.
[0028] In some embodiments of the method, the building
comprises a
plurality of modular units assembled together to form the building.
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[0029] In some embodiments of the method, the building
comprises a
plurality of modular units assembled together to form the building and the
plurality of cladding alignment features are rigidly attached to connectors
affixed to exterior surfaces of each of the plurality of modular units.
[0030] In some embodiments of the method, for one or more of
the
plurality of cladding panels, each of the plurality of fasteners comprises a
tapered slot; each of the plurality of cladding alignment features comprises
an alignment peg; each alignment peg comprises a collar and a head
attached to an end of the collar, the head having a width that is greater than
a width of the collar; and the width of the head is greater than a width of a
narrow end of the tapered slot.
[0031] In some embodiments of the method, for one or more
of the
plurality of cladding panels, each of the plurality of fasteners comprises a
tapered slot; each of the plurality of cladding alignment features comprises
an alignment peg; each alignment peg comprises a collar and a head
attached to an end of the collar, the head having a width that is greater than
a width of the collar; the width of the head is greater than a width of a
narrow
end of the tapered slot; and orienting each tapered slot such that, when the
cladding panel is affixed to the building, the alignment peg is moved into the
narrow end of the tapered slot and held in place by a gravitational force.
[0032] In some embodiments of the method, the substrate
comprises a
waterproof finish panel.
[0033] In some embodiments of the method, the cladding
panel is
attached to the building such that a gap exists between the substrate and
the external surface of the building.
[0034] In some embodiments of the method, the cladding
panel is
attached to the building such that a gap exists between the substrate and
the external surface of the building, the method further comprising filling
the
gap, either partially or entirely, with a rigid insulation layer.
[0035] In some embodiments of the method, each of the plurality of
fasteners is formed in the second surface of the structural frame in a unitary
manner.
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[0036] According to another example aspect, a building is
provided, the
building comprising: a plurality of modular units assembled together to form
the building; a plurality of connectors affixed to exterior surfaces of each
of
the plurality of modular units, the plurality of connectors comprising a
plurality of cladding alignment features, wherein the plurality of cladding
alignment features are rigidly attached to and extend from an external
surface of the building according to a predetermined pattern; and a plurality
of cladding panels. Each of the plurality of cladding panels comprises: a
structural frame; a substrate attached to a first, external, surface of the
structural frame; and a plurality of fasteners that are formed on a second,
internal, surface of the structural frame, the plurality of fasteners being
arranged according to the predetermined pattern, such that each of the
plurality of fasteners is configured for alignment with one of the plurality
of
cladding alignment features. Each of the plurality of fasteners is configured
for attachment to a corresponding one of the plurality of cladding alignment
features. Each of the plurality of cladding panels is affixed to one or more
of
the modular units.
[0037] In some embodiments, the building comprises a
plurality of
modular units assembled together to form the building.
[0038] In some embodiments, the building comprises: a plurality of
modular units assembled together to form the building; and a plurality of
connectors affixed to exterior surfaces of each of the plurality of modular
units, wherein the plurality of cladding alignment features are rigidly
attached
to and extend from the connectors for engagement with the fasteners, and
wherein adjacent ones of the plurality of connectors interlock with each other
to secure adjacent ones of the plurality of modular units together.
[0039] In some embodiments of the building, one or more of
the plurality
of cladding panels comprises one or more openings formed entirely through
a thickness of the substrate thereof, each of the one or more openings
corresponding to an opening formed in the external surface of the building.
[0040] In some embodiments of the building, each of the
plurality of
cladding panels comprises a siding material attached to a surface of the
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substrate that is opposite a surface of the substrate by which the substrate
is
attached to the structural frame.
[0041] In some embodiments of the building, for one or more
of the
plurality of cladding panels, each of the plurality of fasteners comprises a
tapered slot; each of the plurality of cladding alignment features comprises
an alignment peg; each alignment peg comprises a collar and a head
attached to an end of the collar, the head having a width that is greater than
a width of the collar; and the width of the head is greater than a width of a
narrow end of the tapered slot.
[0042] In some embodiments of the building, for one or more of the
plurality of cladding panels, each of the plurality of fasteners comprises a
tapered slot; each of the plurality of cladding alignment features comprises
an alignment peg; each alignment peg comprises a collar and a head
attached to an end of the collar, the head having a width that is greater than
a width of the collar; the width of the head is greater than a width of a
narrow
end of the tapered slot; and each tapered slot is oriented such that, when
one of the plurality of cladding panels is affixed to the external surface of
the
building, the alignment peg is moved into the narrow end of the tapered slot
and held in place by a gravitational force.
[0043] In some embodiments of the building, the substrate comprises a
waterproof finish panel.
[0044] In some embodiments of the building, each of the
plurality of
cladding panels comprises a gap between the substrate and the external
surface of the building when the cladding panel is installed on the exterior
surface of the building.
[0045] In some embodiments of the building, each of the
plurality of
cladding panels comprises a gap between the substrate and the external
surface of the building when the cladding panel is installed on the exterior
surface of the building and the gap is filled, either partially or entirely,
with a
rigid insulation layer.
[0046] In some embodiments of the building, the plurality
of fasteners are
integrally formed in the second surface of the structural frame.
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[0047] According to another example aspect, a cladding panel
for
covering a surface of a building is provided, the cladding panel comprising: a
structural frame; a substrate attached to a first, external, surface of the
structural frame; and a plurality of fasteners that are attached to a second,
internal, surface of the structural frame, the plurality of fasteners being
arranged according to a predetermined pattern; wherein each of the plurality
of fasteners is configured for attachment to a corresponding one of a
plurality
of cladding alignment features on an external surface of the building; and
wherein the plurality of cladding alignment features are arranged on the
external surface of the building according to the predetermined pattern, such
that each of the plurality of fasteners is configured for alignment with, and
attachment to, one of the plurality of cladding alignment features.
[0048] In some embodiments, the cladding panel comprises one
or more
openings formed entirely through a thickness of the substrate, each of the
one or more openings corresponding to an opening formed in the external
surface of the building.
[0049] In some embodiments, the cladding panel comprises a
siding
material attached to a surface of the substrate opposite a surface of the
substrate by which the substrate is attached to the structural frame.
[0050] In some embodiments of the cladding panel, the building
comprises a plurality of modular units assembled together to form the
building.
[0051] In some embodiments of the cladding panel, the
plurality of
cladding alignment features are rigidly attached to connectors affixed to
exterior surfaces of each of the plurality of modular units.
[0052] In some embodiments of the cladding panel, each of
the plurality
of fasteners comprises a tapered slot; each of the plurality of cladding
alignment features comprises an alignment peg; each alignment peg
comprises a collar and a head attached to an end of the collar, the head
having a width that is greater than a width of the collar; and the width of
the
head is greater than a width of a narrow end of the tapered slot.
[0053] In some embodiments of the cladding panel, each
tapered slot is
oriented such that, when the cladding panel is affixed to the building, the
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narrow end of the tapered slot is configured such that gravity acts to retain
the alignment peg within the narrow end of the tapered slot.
[0054] In some embodiments of the cladding panel, the
substrate
comprises a waterproof finish panel.
[0055] In some embodiments, the cladding panel comprises a
gap
between the substrate and the external surface of the building.
[0056] In some embodiments of the cladding panel, the gap
is filled,
either partially or entirely, with a rigid insulation layer.
[0057] In some embodiments of the cladding panel, the
plurality of
fasteners are integrally formed in the second surface of the structural frame.
[0058] According to another example aspect, a system for
covering an
exterior surface of a building is provided, the system comprising a plurality
of
any of the cladding panels described herein; wherein the building comprises
a plurality of assembled modular units; and wherein each of the plurality of
cladding panels is affixed to one or more of the modular units.
[0059] In some embodiments of the system, one or more of
the cladding
panels has a width of at least two of the plurality of modular units that are
laterally adjacent to each other.
[0060] According to another example aspect, a method of
covering an
external surface of a building is provided, the method comprising: producing
a cladding panel comprising a structural frame, a substrate attached to a
first, external, surface of the structural frame, and a plurality of fasteners
that
are attached to a second, internal, surface of the structural frame, the
plurality of fasteners being arranged according to a predetermined pattern;
the method further comprising: attaching each of the plurality of fasteners to
a corresponding one of a plurality of cladding alignment features on the
external surface of the building; and arranging the plurality of cladding
alignment features on the external surface of the building according to the
predetermined pattern, such that each of the plurality of fasteners is
configured for alignment with, and attachment to, one of the plurality of
cladding alignment features.
[0061] In some embodiments of the method, producing the
cladding
panel comprises forming one or more openings through an entire thickness
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of the substrate, each of the one or more openings corresponding to an
opening formed in the external surface of the building.
[0062] In some embodiments, the method comprises attaching
a siding
material to a surface of the substrate opposite a surface of the substrate by
which the substrate is attached to the structural frame.
[0063] In some embodiments of the method, the building
comprises a
plurality of modular units assembled together to form the building.
[0064] In some embodiments of the method, the plurality of
cladding
alignment features are rigidly attached to connectors affixed to exterior
surfaces of each of the plurality of modular units.
[0065] In some embodiments of the method, each of the
plurality of
fasteners comprises a tapered slot; each of the plurality of cladding
alignment features comprises an alignment peg; each alignment peg
comprises a collar and a head attached to an end of the collar, the head
having a width that is greater than a width of the collar; and the width of
the
head is greater than a width of a narrow end of the tapered slot.
[0066] In some embodiments of the method, each tapered slot
is oriented
such that, when the cladding panel is affixed to the building, the narrow end
of the tapered slot aligned so that gravity acts to retain the alignment peg
within the narrow end of the tapered slot.
[0067] In some embodiments of the method, the substrate
comprises a
waterproof finish panel.
[0068] In some embodiments of the method, the cladding
panel is
attached to the building such that a gap exists between the substrate and
the external surface of the building.
[0069] In some embodiments, the method comprises filling
the gap, either
partially or entirely, with a rigid insulation layer.
[0070] In some embodiments of the method, the plurality of
fasteners are
integrally formed in the second surface of the structural frame.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0071] FIG. 1 is an isometric rear view of an example
embodiment of a
cladding panel for mounting to an exterior of a structure, particularly to a
structure constructed from a plurality of modular units.
[0072] FIG. 2 is a top view of the example cladding panel of FIG. 1.
[0073] FIG. 3 is a side view of the example cladding panel
of FIG. 1.
DETAILED DESCRIPTION
[0074] The accompanying figures and description are merely
examples of
a single example embodiment for modular cladding panels and cladding
systems for buildings, as well as methods of production, assembly, and use
therefor. As such, the foregoing description and accompanying figures are
illustrative and are not to be used to limit the scope of the presently
disclosed subject matter.
[0075] Unless defined otherwise, all technical and
scientific terms used
herein have the same meaning as commonly understood to one having
ordinary skill in the art to which the presently disclosed subject matter
belongs. Although, any methods, devices, and materials similar or equivalent
to those described herein can be used in the practice or testing of the
presently disclosed subject matter, representative methods, devices, and
materials are now described.
[0076] Following long-standing patent law convention, the
terms "a", "an",
and "the" refer to "one or more" when used in this application, including the
claims. Thus, for example, reference to "a fastener hole" can include a
plurality of such fastener holes, and so forth.
[0077] Unless otherwise indicated, all numbers expressing quantities of
length, diameter, width, and so forth used in the specification and claims are
to be understood as being modified in all instances by the terms "about" or
"approximately". Accordingly, unless indicated to the contrary, the numerical
parameters set forth in this specification and attached claims are
approximations that can vary depending upon the desired properties sought
to be obtained by the presently disclosed subject matter.
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[0078] As used herein, the terms "about" and
"approximately," when
referring to a value or to a length, width, diameter, temperature, time,
volume, concentration, percentage, etc., is meant to encompass variations of
in some embodiments 20%, in some embodiments 10%, in some
embodiments 5%, in some embodiments 1%, in some embodiments
0.5%, and in some embodiments 0.1% from the specified amount, as such
variations are appropriate for the disclosed apparatuses and devices.
[0079] The term "comprising", which is synonymous with
"including"
"containing" or "characterized by" is inclusive or open-ended and does not
exclude additional, unrecited elements or method steps. "Comprising" is a
term of art used in claim language which means that the named elements
are essential, but other elements can be added and still form a construct
within the scope of the claim.
[0080] As used herein, the phrase "consisting of" excludes
any element,
step, or ingredient not specified in the claim. When the phrase "consists of"
appears in a clause of the body of a claim, rather than immediately following
the preamble, it limits only the element set forth in that clause; other
elements are not excluded from the claim as a whole.
[0081] As used herein, the phrase "consisting essentially
of" limits the
scope of a claim to the specified materials or steps, plus those that do not
materially affect the basic and novel characteristic(s) of the claimed subject
matter.
[0082] With respect to the terms "comprising", "consisting
of", and
"consisting essentially of", where one of these three terms is used herein,
the
presently disclosed and claimed subject matter can include the use of either
of the other two terms.
[0083] As used herein, the term "and/or" when used in the
context of a
listing of entities, refers to the entities being present singly or in
combination.
Thus, for example, the phrase "A, B, C, and/or D" includes A, B, C, and D
individually, but also includes any and all combinations and sub-
combinations of A, B, C, and D.
[0084] FIG. 1 is an isometric rear view of an example
embodiment of a
cladding panel system, generally designated 10, the system including a
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plurality of cladding panels, generally designated 100, which are suitable for
attaching over an exterior of a building (e.g., as a cover for any suitable
structure, including a residential and/or commercial structure) to resist
and/or
prevent the intrusion of wind, precipitation (e.g., rain, snow, sleet, etc.),
or
other flying objects or debris through the exterior surface of the building.
As
shown in FIG. 1, each cladding panel 100 comprises a substrate, or finish
panel 110, that is rigidly attached to a lightweight structural frame 130. Non-
limiting examples of materials that can be used in constructing and/or
forming the finish panel 110 include plastics, metals, ceramic (e.g., cement
and/or fiber cement), composite materials, wood (e.g., including man-made
wood derivatives), and combinations thereof.
[0085] The structural frame 130 can have any suitably rigid
construction,
without limitation, based on the environmental conditions to which the
cladding panel 100 will be exposed when installed on the building. In the
example embodiment shown, the structural frame 130 comprises a plurality
of vertical stiffeners 132 and a plurality of horizontal stiffeners 134. The
vertical stiffeners 132 are attached to the horizontal stiffeners 134 at
substantially 900 angles (e.g., +/- 5 , +/- 2 , +/- 1 , exactly 90 , and the
like,
allowing for manufacturing and assembly tolerances). The structural frame
130 may also have stiffeners, instead of and/or in addition to the vertical
stiffeners 132 and the horizontal stiffeners 134, that are arranged relative
to
other stiffeners and/or the gravity vector at neither 0 or 90 , such as
between about 15 and about 75 , between about 30 and about 60 , and
about 450. Since the cladding panels 100 are supported by the modular
unit(s) of the building to which they are each attached, respectively, the
cladding panels 100 are not, in some embodiments, load=bearing structures
of the building and, as such, the quantity of stiffeners can be minimized
(e.g.,
only providing a sufficient quantity to achieve a specified rigidity for a
cladding panel 100 in a particular installation environment). Non-limiting
example of materials that can be used in the structural frame 130 can
include plastics, metals, composite materials, wood (e.g., including man-
made wood derivatives), and combinations thereof.
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[0086] In some example embodiments, the finishing panel 110
is a
substrate (e.g., a non-decorative panel) and acts as a surface to which any
suitable type of siding material (e.g., wood boards, lap shingles, vinyl
siding,
masonry, stone, faux masonry, faux stone, and the like) may be affixed. The
structural frame 130 is designed to have sufficient rigidity such that the
cladding panel 100 can be securely (e.g., rigidly) attached onto the exterior
surface of the modular unit(s) of the building. In some embodiments, the
structural frame 130 may be designed to allow for amounts of deformation of
the cladding panel 100 that would not damage (e.g., as may occur due to
plastic deformation thereof) the finish panel 110. In some embodiments, the
structural frame 130 is sufficiently rigid that the structural frame 130 is
not
deformed (e.g., only negligibly and/or imperceptibly) by the weight of the
finishing panel 110 when the cladding panel 100 is suspended in the air
(e.g., such as may be necessary during installation of the cladding panel
onto the exterior of the modular unit(s) of the building).
[0087] In the example embodiment shown in FIG. 1, each
finish panel
100 of the finish panel system 10 has two openings, generally designated
112, formed through the entire thickness of the finish panel 100. The
structural frame 130 is designed such that no portion of the structural frame
130 (e.g., no vertical stiffeners 132 or horizontal stiffeners 134) is visible
through the opening 112 from the side of the structural frame 130 on which
the finish panel 110 is attached. The quantity of openings 112 in each finish
panel 110 (and, therefore necessarily, in each cladding panel 100) is
generally determined based on the number of openings in the exterior wall
and/or surface of the modular unit(s) to which the cladding panel 100 is
attached during construction of the building. Non-limiting examples of such
openings can include windows, doors, vents, and the like. As such, each
cladding panel 100 is specifically manufactured (e.g., during off-site pre-
fabrication) such that the position and size of any openings 112 formed in
each cladding panel 100 corresponds precisely to the position and size of
any openings formed in the exterior of the modular unit(s) over which the
cladding panel 100 is to be affixed. In embodiments in which the exterior wall
of the modular unit(s) over which the cladding panel 100 is to be affixed has
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no openings formed therein, the cladding panel 100 may also have no
openings 112 therein; thus, in some embodiments, one or more cladding
panels 100 of the cladding panel system 10 are devoid of any openings 112.
In some embodiments, the cladding panel may have, formed on an exterior
surface thereof (e.g., on a surface opposite the structural frame 130), a faux
opening that is merely decorative. Such a faux opening may thus be
designed to have a substantially identical appearance to that of an opening
112 formed on the same cladding panel 100 and/or on another cladding
panel 100 of the cladding panel system 10, but such faux opening is located
on the cladding panel 100 at a position behind which, when the cladding
panel 100 is attached to the building, there is no opening formed in the
external wall of the modular unit(s) of the building. Such faux openings can
be advantageous for maintaining symmetry of an exterior of a building. In
some embodiments, the cladding panel 100 is pre-fabricated to have a solid
finish panel 110 and openings 112 may be cut through the finish panel 110
on-site (e.g., away from the prefabrication site, before or after the cladding
panel 100 is attached to the building) to accommodate openings 112 formed
in the exterior wall of the modular unit(s) over which the cladding panel 100
is designated to be affixed. In such embodiments, it is advantageous for at
least the vertical stiffeners 132 and/or horizontal stiffeners 134 of the
structural frame 130 to be movable (e.g., to a position outside of the opening
112 to be cut) and/or for such vertical stiffeners 132 and/or horizontal
stiffeners 134 to be provided redundantly so that the structural frame 130 is
not compromised.
[0088] Fasteners 200 are rigidly affixed according to a predetermined
pattern on and across the structural frame 130 (e.g., on the vertical
stiffeners
132 and/or horizontal stiffeners 134). The fasteners 200 can be of any
suitable type and/or sort that is compatible with a corresponding cladding
alignment feature rigidly attached to the exterior of the building (e.g., such
as
connectors 2) on which the cladding panel 100 is designated to be installed.
These cladding alignment features are rigidly affixed to the exterior of the
building according to the same predetermined pattern as are the fasteners
200, such that the fasteners 200 of the cladding panel 100 aligns with the
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cladding alignment features on the exterior of the building. In the example
embodiment shown, the fasteners 200 are tapered slots formed in a bracket
that are configured to be inserted over an alignment peg in a connector 2,
which is rigidly affixed to the exterior of the building and, particularly, to
lower
and upper edges and/or corners of each modular unit for a building being
constructed of modular units. As such, the fasteners 200 are positioned such
that the tapered slots associated therewith are positioned to that the
alignment peg of the connector 2 rests within a wider portion of the tapered
slot of the fastener 200; the cladding panel 100 is shifted (e.g., vertically,
in
the direction of the gravity vector) so that the alignment peg moves from the
wider portion of the tapered slot into the narrower portion of the tapered
slot,
meaning that the alignment peg is positioned within the narrow end of the
tapered slot. The fastener 200 is formed such that the alignment peg cannot
be removed from the narrow portion, or end, of the tapered slot without
shifting the cladding panel 100 in a reverse direction (e.g., vertically, in
the
direction opposite the gravity vector) so that the alignment peg is again
positioned in the wider portion of the tapered slot. Thus, the wider portion
of
the tapered slot has a width that is wider than the diameter of the alignment
peg and the narrower portion of the tapered slot has a width that is narrower
than the diameter of the alignment peg, such that the alignment peg can be
inserted within and removed from the tapered slot of the fastener 200 only
via the wider portion. In such embodiments, the alignment peg has a collar
that extends away from the exterior surface of the connector 2 to which the
cladding panel 100 is to be affixed and, at an end of the collar away from the
exterior surface, a head that extends away from the collar and has a width
(e.g., diameter) that is greater than the width (e.g., diameter) of the
collar,
such that the head can extend into the tapered slot of the fastener 200.
[0089] In some embodiments, the positioning of the
alignment peg and
the tapered slots is reversed from that which is described hereinabove, such
that the tapered slots are rigidly affixed to the exterior surface of the
connector 2 to which the cladding panel 100 is to be affixed and the
alignment pegs are rigidly attached to the structural frame 130 (e.g., to the
vertical stiffeners 132 and/or horizontal stiffeners 134). In some
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embodiments, the tapered slots are formed so that the force of gravity will,
during installation, pull the cladding panel 100 in a vertically downward
direction to engage the alignment peg within the narrow portion of the
tapered slot of the fastener 200. The fasteners 200 and the cladding
alignment features of the connectors 2 provided and described herein are
merely examples and different kinds of attachments, including lockable
attachments, are also suitable for use herein. In some embodiments, the
tapered slots have a pivoting, or rotating, member (e.g., in the form of a
finger or arm) that pivots from a closed position, in which the pivoting
member blocks some or all of the tapered slot of the fastener 200, into an
open position, in which the pivoting member is configured to allow passage
of the alignment peg into the narrower portion of the tapered slot, then the
pivoting member returns to the closed position (e.g., by being spring loaded
or gravity assisted), such that the alignment peg cannot be removed from the
narrower portion of the tapered slot without first moving (e.g., manually,
with
a tool, etc.) the pivoting member into the open position, such that the
pivoting member no longer obstructs the removal of the alignment peg from
the narrower portion of the tapered slot (e.g., as may be necessary for
removal of a cladding panel 100 from the building). As such, the pivoting
member is configured to act as a lock of sorts.
[0090] FIG. 2 is a top view of a cladding panel 100
attached to an
external surface of a volumetric box 1 (e.g., a modular unit, such as is used
during construction of a building constructed by assembling and
interconnecting together a plurality of modular units according to a
construction plan, diagram, schematic, blueprints, and the like). Examples of
structures contained within and/or defining the size of such volumetric boxes
1 include floors, ceilings, and walls that define and/or create interior one
or
more spaces within the building. These volumetric boxes 1 are then stacked
and arranged in specific configurations per the schematics (e.g., design
blueprints) for the building being constructed. The cladding panels 100 are
advantageously pre-fabricated at a site (e.g., a factory) located a distance
away from (e.g., by a distance requiring transport of the cladding panels 100
over public roadways) the site where the building to which the cladding
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panels 100 will be affixed is being constructed. After off-site
prefabrication,
the cladding panels 100 are transported to the site where the building is
being constructed and, optionally, transferred to a staging area thereof.
Once the cladding panels 100 are on-site at the construction site, the
cladding panels 100 are moved (e.g., lifted or hoisted) into a position
adjacent to an installation position on the building, the installation
position
being where the cladding panel 100 is designated for affixing to the exterior
of the building being constructed. Once adjacent to the installation position,
the cladding panels 100 are moved into the installation position and are
securely attached to the building to cover the exterior surface of the
building,
or at least a portion of the exterior surface of the building. In some
embodiments, the cladding panels 100 are pre-fabricated and/or stored for
transport in an order of installation on the exterior of the building to which
the
cladding panels 100 are to be affixed, such that the cladding panels 100 can
be installed on and/or over the exterior surface of the building in the order
of
manufacture, in the order of arrival at the construction site, and/or in the
order of arrangement within a plurality of such cladding panels 100 that are
transported together to the construction site (e.g., in such a manner that
multiple cladding panels 100 can be said to arrive at the construction site
substantially simultaneously.
[0091] The cladding panels 100 are configured for assembly
over the
exterior surface of the building (e.g., over a portion of a volumetric box 1,
all
of a volumetric box 1, portions of multiple volumetric boxes 1, all of one
volumetric box 1 and one or more portions of at least one other volumetric
box 1, or all of multiple volumetric boxes 1) to minimize the number of
vertical seams present between laterally adjacent cladding panels 100 of the
cladding panel system 10 on the finished building by spanning multiple
volumetric boxes 1, or modular units. In some embodiments, the lateral
sides, or ends, of the finish panel 110 of one or more of (e.g., each and/or
all
of) the cladding panels 100 may be staggered (e.g., have a geometric, non-
linear, lateral end face, or edge) such that the lateral side of a first
cladding
panel 100 is shaped to interleave with a matching (e.g., having a reverse, or
mirrored) shape of the lateral end face, or edge, thereof of a laterally
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adjacent (e.g., adjoining) second cladding panel 100, such that the vertical
seam formed between laterally adjacent cladding panels is broken up (e.g.,
discontinuous, such as in the case of not being a single vertical line) along
the height (e.g., along the lateral edge) of the cladding panel 100, such that
one or more of the lateral edges of the cladding panel 100 is subdivided into
and/or formed a plurality of shorter vertical seams (e.g., edges) that may be
less easily visible to an observer standing outside of the building.
Horizontally-extending joints formed between vertically adjacent cladding
panels 100 can be expressed (e.g., left visible) or hidden, for example, by
partially overlapping (e.g., in the style of a tongue-and-groove interface) a
lower cladding panel 100 with an upper cladding panel 100.
[0092] As shown in FIG. 3, the cladding panels 100 of the
cladding panel
system 10 form, when affixed to an exterior of a volumetric box 1, a gap,
generally designated 112, between the exterior weather-resistive surface of
the volumetric box 1 and the adjoining surface of the cladding panel 100
(e.g., the surface of the cladding panel 100 that faces the volumetric box 1
when affixed thereto). In some embodiments, this gap 112 is left vacant and
is operable as an air gap that can advantageously act as a rainscreen that is
beneficial to the longevity of the exterior weather-resistive surface of the
volumetric box 1. In some embodiments, however, the gap 112 may be filled
with substantially rigid insulation (e.g., in sheet form, which can attach to
the
cladding panel 100 on a surface thereof, opposite the finish panel 110 or
substrate, within the gap 112 or injected within the gap 112, such as in the
manner of a foam). In such embodiments having insulation within the gap
112, a substantially continuous insulation barrier may be provided between
the finish panel 110 and the exterior weather-resistive surface of the
volumetric box 1 to improve the insulation of the building when fully
constructed, thereby improving the energy loss characteristics of the building
(e.g., by reducing heat loss during periods when the ambient temperature is
less than an interior temperature of the building or heat gain during periods
when the ambient temperature is greater than an interior temperature of the
building).
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[0093] In the example embodiment shown in FIG. 3, a
connector 2 is
rigidly attached to a surface (e.g., at a corner and/or along an edge) of a
volumetric box 1. In order to provide isolation (e.g., acoustic, vibratory,
and
the like) between vertically adjacent volumetric boxes 1, it is advantageous
for a vibration-reducing layer, or pad 4 attached to the bottom surface of the
volumetric box 1, such that the pad 4 will be positioned between vertically
stacked volumetric boxes 1, such that the pad 4 is in direct contact with the
volumetric boxes 1 positioned directly below and directly above the pad 4.
The connector 2 can be of the sort disclosed in U.S. Provisional Patent No.
63/112,484, the contents of which are incorporated herein in their entirety.
Extending from the connector 2 is a cladding alignment feature 3, which is
shown in this example embodiment in the form of a peg that protrudes from
the surface of the connector and has a collar portion that is attached
directly
to the connector 2 and a head portion that is attached directly to the collar
and is spaced apart from the connector 2 by the collar; the head has a
diameter that is larger than the diameter of the collar.
[0094] The structural frame 130 has, as noted elsewhere
herein, vertical
stiffeners 132 and horizontal stiffeners 134, which are arranged substantially
orthogonally to each other. At least some (e.g., all) of the vertical
stiffeners
130 have a slot formed in a surface thereof. The slot has a tapering cross-
sectional shape, such that the diameter of the head of the cladding
alignment feature 3 is wider than the narrow end of the slot, such that the
cladding alignment feature 3 cannot be removed from the slot of the vertical
stiffener 132 unless vertical stiffener 132 is moved vertically, relative to
the
cladding alignment peg 3, such that the cladding alignment feature 3 is
within the wider portion of the slot formed in the vertical stiffener 132; in
some embodiments, the entire cladding panel 100 must be moved vertically
for the cladding alignment feature 3 to be able to be removed from the slot
formed in the vertical stiffener 132. In order for the horizontal stiffeners
134
to be attached to the vertical stiffeners 132, some or all of the vertical
stiffeners 132 have a bracket 133 attached to a surface thereof (e.g., an
opposite surface of the vertical stiffener 132 from the side in which the slot
is
formed), the bracket 133 having a channel into which one of the horizontal
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stiffeners 134 can be inserted for rigid attachment to the vertical stiffener
132.
[0095] In the example embodiment shown in FIG. 3, the gap
112 is
defined by at least the thickness of the vertical stiffener 132 and the
bracket
133. The horizontal stiffener 134 has a cross-sectional shape in the form of a
step. The word "step," as used immediately hereinabove, means a cross-
sectional profile defined by first and second planar structures that are
connected together at the adjacent edges thereof by a third planar structure
that is inclined or orthogonal to the first and second planar structures, the
first and second planar structures extending away from the third planar
structure in opposite directions; in some embodiments, the first and second
planar structures are positioned within planes that are parallel but offset
from
each other. As such, the gap 112 has a thickness that is greater than a
combined thickness of one of the vertical stiffeners 132 and one of the
horizontal stiffeners 134.
[0096] The horizontal stiffeners 134 are rigidly attached
to the finish panel
110 (e.g., on the surface of the finish panel 110 that, when installed on the
exterior surface of the building, faces towards the gap 112). Thus, in some
embodiments, the vertical stiffeners 132 may be attached to the exterior
surface of the building separately from (e.g., individually, separate from)
the
horizontal stiffeners 134. In some embodiments, the horizontal stiffeners 134
are rigidly attached to the vertical stiffeners 132 before the cladding panel
100 is installed to the exterior surface of the building. The finish panel 110
is
advantageously constructed out of a waterproof material, such that water
cannot pass through the finish panel 110 and be exposed to the gap 112, or
to any insulation present within the gap 112. The components of the
structural frame 130 are advantageously made of a material that does not
corrode and/or degrade when exposed to water; examples of such materials
can include, for example, aluminum, plastic, wood, and the like. In some
embodiments, the components of the structural frame 130 can be partially
and/or fully encapsulated to prevent corrosion caused by exposure to water
before and/or while installed on the exterior surface of the building.
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[0097] The present subject matter can be embodied in other
forms
without departure from the spirit and essential characteristics thereof. The
embodiments described therefore are to be considered in all respects as
illustrative and not restrictive. Although the present subject matter has been
described in terms of certain specific embodiments, other embodiments that
are apparent to those of ordinary skill in the art are also within the scope
of
the present subject matter.
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