WO2009026173A1

WO2009026173A1 - Shingle-style cladding and system for mounting the same

Info

Publication number: WO2009026173A1
Application number: PCT/US2008/073370
Authority: WO
Inventors: Guillaume Martin; Koop T. Kuperus
Original assignee: Hunter Douglas Industries B.V.
Priority date: 2007-08-22
Filing date: 2008-08-15
Publication date: 2009-02-26

Abstract

A cladding system includes a plurality of panels and a plurality of standoffs arranged to create an effectively weather-resistant structure. In one implementation, the panels are arranged to also provide a shingle-based aesthetic in a cladding system. A manufacturer can arrange the plurality of panels in such a way as to minimize not only exposure/view of the plurality of standoffs, but also the number of standoffs used to secure the panels in the cladding system. The cladding system can be mounted to any building structure to form an exterior weather barrier and/or aesthetic facade, as well as to any one or more of an interior wall, ceiling, or floor.

Description

SHINGLE-STYLE CLADDING AND SYSTEM FOR MOUNTING SAME

The Field of the Invention The present invention relates generally to systems, methods, and apparatus for cladding a support structure with one or more panels. Discussion of the Relevant Art

Designers and architects will sometimes add to the functional and/or aesthetic characteristics of a given structure by cladding the structure with one or more sets of panels. This is at least partly since there is sometimes more flexibility with how the given panel (or set of panels) is designed, compared with the original structure to be clad. For example, a manufacturer can assemble or otherwise create virtually any size, shape, gauge, color, or the like of a given panel (or sets of panels). The manufacturer can subsequently mount the panel or sets of panels to virtually any structure, whether new or old, in virtually any degree of permanence.

The ability to clad a structure with panels provides a number of structural advantages including various advantages in insulation, as well as general shielding of the elements. The ability to manipulate panels to create a wide range of styles, however, provides designers with a virtually endless array of options in terms of improving or otherwise changing the internal or external aesthetics of the structure. Specifically, the designer or manufacturer can modify the color, texture, or even shape of a given structure simply by modifying such features in the panels used to clad the given structure.

In general, panels used as cladding can be composed of a wide range of different materials. For example, panels can be made of any number of naturally or synthetically occurring metallic, glass, or resin-based materials, such as polyvinyl chloride or "PVC"; polyacrylate materials such as poly (methyl methacrylate) or

"PMMA"; polyester materials such as poly (ethylene-co-cyclohexane 1,4-dimethanol terephthalate), or "PET"; poly (ethylene-co-cyclohexane 1,4-dimethanol terephthalate glycol), or "PETG"; glycol modified polycyclohexylenedimethlene terephthalate, or

"PCTG"; as well as polycarbonate, or "PC", materials, and combinations thereof. More recently, resin-based panels have become more popular due to their relative flexibility, relative light weight, and relative ease by which resins can be modified or formed into various decorative shapes at comparatively low cost. Resins can also provide more flexibility compared with glass or other conventional panels at least in terms of color, degree of texture, gauge, and impact resistance. Additionally, resins may provide certain advantages in terms of recycling and reuse.

One will appreciate, therefore, that the type of material used to clad a given structure can affect the level of difficulty in the mounting and designing process. For example, metallic and glass-based panels tend to be much less flexible and less useful in terms of design flexibility than resin-based counterparts. On the other hand, resin- based panels have a tendency to be more sensitive to the elements in terms of expansion and contraction. This makes certain conventional mounting mechanisms and apparatus, which are suitable for glass or metals, generally unsuitable with resin- based panels over any useful period of time. In particular, conventional mounting apparatus and methods typically do not account for the significantly greater thermal expansion/retraction resin-based panels may undergo when compared to metal or other conventional types of panels. Because conventional mounting mechanisms and apparatus do not compensate for this additional expansion and/or contraction over time, their use can ultimately result in damage to resin-based panels. For example, mounting mechanisms and apparatus that are too loose due to retraction of a panel can result in inappropriate shifting of the panel, which may cause the panel to crack. Similarly, mounting mechanisms and apparatus that are too tight due to the expansion of a panel may result in one or more of the components digging into the panel, which may result in cracks or fissures in the panel.

One conventional mounting apparatus for cladding a structure involves various standoff apparatus configured to secure each corner of a given panel to a structure. To this end, the manufacturer will typically perforate the corners of a panel, mount corresponding standoffs to a structure, and then secure each of the perforated corners of the panel to each standoff. Thus, each panel includes a relatively inflexible mounting of each panel corner with one of the different standoffs. In addition, since each corner is in a relatively fixed position, the fixed mounting at each position can increase the possibility of damage to the resin-based panel during contraction and expansion. Alternative systems and apparatus for mounting panels to a structure include constructing a frame into which each panel can be inserted. Although the frame can be configured with a certain amount of flexibility in terms of accommodating expansion and contraction, the frame approach tends to limit cladding structures to essentially right-angle formations. If the designer would like to use a more creative panel formation or alignment, the designer will also often need to create an elaborate, corresponding frame structure. One will appreciate that such alternative types of frames can be cost-prohibitive, especially for more elaborate panel cladding designs.

Furthermore, conventional mounting mechanisms and apparatus typically lack the ability to accommodate curved and/or angled panels. Specifically, conventional mounting mechanisms and apparatus are often configured to secure planar panels in upright or horizontal positions. Thus, when used with curved or angled panels, the mounting interface created by the mounting mechanisms and apparatus may tend to dig into or otherwise damage the panel.

In addition to the relative inflexibility of conventional mounting mechanisms and apparatus, conventional mounting mechanisms and apparatus are often unsightly, too noticeable, or do not provide an appropriate aesthetic for desired design environments. For example, a frame is visible and covers a portion of a panel in order to securely hold the panel. Recently, however, designers often prefer that mounting apparatus, such as frames, be hidden. This is due at least in part because the unpleasant aesthetic of conventional mounting mechanisms and apparatus is often magnified when used with translucent or other resin-based panels that magnify texture, light, color, and form. Thus, conventional mounting mechanisms and apparatus may be unappealing to designers and architects seeking to obtain a certain aesthetic by using resin-based panels. While the use of resin-based panels provide several advantages when compared with decorative cast or laminated glass materials, the use of resin-based panels as a cladding may also present drawbacks not present when using panels formed from conventional materials. For example, resin-based panels can tend to deflect or bow when exposed to stresses. This can be problematic when such resin- based panels are used as outdoor cladding on a structure and exposed to wind and other elements. One conventional solution to avoid deflection or bowing of resin panels is to increase the strength of the panel by increasing its gauge. Increasing the gauge of a panel, however, can dramatically increase the cost of the already expensive decorative architectural panels.

Accordingly, there are a number of disadvantages in conventional panel mounting and cladding systems that can be addressed.

BRIEF SUMMARY OF THE INVENTION Implementations of the present invention provide systems, methods, and apparatus for mounting panels as a cladding structure in a unique formation or alignment, but nevertheless suitable as a shield from the elements. In particular, implementations of the present invention allow a manufacturer to clad a given structure with panels (e.g., comprising resiliently flexible materials) configured in a "shingle- style" formation. The manufacturer can mount the panels as a cladding structure in a manner that minimizes the effects of expansion and contraction a given panel can undergo outdoors. The cladding structures described herein provide a number of insulation and weather-shield benefits, in addition to providing aesthetic advantages.

For example, a cladding system for cladding a pre-existing structure with weather-resistant, resin panels in accordance with an implementation of the present invention can include a plurality of resin panels, including a base panel and plurality of overlapping panels that at least partially overlap the base panel to form a weather resistant facade for the pre-existing structure. The cladding system further includes a standoff component attached to the base panel at a plurality of corners. In particular, at least one standoff component rigidly affixes a first corner of the base panel to the pre-existing structure and flexibly affixes one or more overlapping panels to the base panel and to the pre-existing structure.

In addition, a cladding system for cladding a pre-existing structure with a plurality of resin panels in accordance with another implementation of the present invention can include a plurality of resin panels mounted to a support structure as a decorative and functional facade for the support structure. At least one corner of a resin panel is rigidly secured to the support surface. At least a second corner is flexibly secured to the support surface above a rigidly secured corner of another panel. Additionally, at least a third corner is propped away from the support surface. Furthermore, a method of mounting a plurality of panels about a pre-existing structure to create a weather resistant, aesthetically pleasing cladding in accordance with an implementation of the present invention can include rigidly affixing a first panel to pre-existing structure with a standoff component. The method can also include flexibly affixing a second panel to the structure with the standoff component, such that at least a portion of the second panel overlaps the first panel. In addition, the method can include flexibly affixing a third panel to the standoff component such that at least a portion of the third panel overlaps the first panel and the second panel. Furthermore, the method can include positioning a fourth panel over the standoff component such that at least a portion of the fourth panel overlaps the first panel, the second panel, and the third panel.

Additional features and advantages of exemplary implementations of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such exemplary implementations. The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

Figure IA illustrates a schematic diagram of a cladding system secured to a wall that has been constructed using a plurality of overlapping resin-based panels in a shingle- style formation in accordance with an implementation of the present invention;

Figure IB illustrates a schematic diagram of a cladding system secured to a ceiling that has been constructed using a plurality of overlapping resin-based panels in a shingle- style formation in accordance with an implementation of the present invention;

Figure 2 illustrates an exploded perspective view of some of the parts and components of the cladding system shown in Figure IA;

Figure 3 illustrates a plan view of another panel configuration that can be used in conjunction with a cladding system shown in Figures IA or IB; and

Figure 4 illustrates a side, cross-sectional view of a joint of the cladding system of Figure IA taken along the line 4-4 shown in Figure IA.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is directed toward systems, methods, and apparatus for mounting panels as a cladding structure in a unique formation or alignment, but nevertheless suitable as a shield from the elements. In particular, implementations of the present invention allow a manufacturer to clad a given structure with panels (e.g., comprising resiliently flexible materials) configured in a "shingle- style" formation.

The manufacturer can mount the panels as a cladding structure in a manner that minimizes the effects of expansion and contraction a given panel can undergo outdoors. The cladding structures described herein provide a number of insulation and weather- shield benefits, in addition to providing aesthetic advantages.

As will be appreciated more fully herein, implementations of the present invention provide the ability to mount panels as a cladding structure or facade in a unique formation that, while providing a pleasing aesthetic, can also increase the strength and/or durability of the panels without increasing the gauge of the panels. Thus, implementations of the present invention can provide structurally sound cladding and facade structures capable of resisting deflection when exposed to wind or other forces using relatively thin and cost efficient resin-based panels. In addition, implementations of the present invention can provide structurally sound cladding and facade structures that can provide an adequate barrier from rain and/or other elements for the pre-existing support structure to which it is attached. Furthermore, implementations of the present invention can increase the aesthetic appeal of the cladding structures by reducing both the visibility and number of mounting structures, which tend to detract from the aesthetic provided by the use of decorative architectural panels.

Figures IA- IB illustrate cladding structures 100a, 100b constructed using a plurality of panels 105 aligned in a shingle-style formation in accordance with an implementation of the present invention. In particular, Figure IA shows a cladding system 100a formed from a plurality of panels 105(a, b, etc.) mounted to a wall structure. By contrast, Figure IB illustrates a cladding system 100b formed from a plurality of panels 105 mounted to a ceiling structure. As shown in Figures 1A-1B, the panels 105 of both cladding structures 100a/100b are aligned in a shingle-style or overlapping formation, as described in greater detail below. As used herein, the term "panel" refers primarily to resin-based panels, such as panels comprising materials of one or more layers or sheets formed from any one of the following thermoplastic polymers (or alloys thereof). Specifically, such materials include but are not limited to, polyethylene terephthalate (PET), polyethylene terephthalate with glycol-modification (PETG), acrylonitrile butadiene-styrene (ABS), polyvinyl chloride (PVC), polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), polycarbonate (PC), styrene, polymethyl methacrylate (PMMA), polyolefins (low and high density polyethylene, polypropylene), thermoplastic polyurethane (TPU), cellulose -based polymers (cellulose acetate, cellulose butyrate, or cellulose propionate), or the like. In addition to resin-based panels, the term "panel," as used herein, also comprises other materials including metallic, wood, or glass materials. Specifically, in at least one implementation, each panel 105(a-i, etc.) used in a particular cladding structure is selected based on the given panel's flexibility and/or resilience. That is, in such an implementation, the panel 105 will be selected so that it has sufficient elasticity to allow the panel to be bent and held at a desired angle or curvature, but will return to its original shape when the released from stress. Such appropriately rigid — and at the same time flexible/resilient — materials include the resin-based materials described above, as well as various wood and/or metallic (e.g., aluminum, titanium, etc.) laminates, as well as fiberglass materials (or laminates thereof), whereby the combination of materials provides the needed resilience. Of course, elasticity or the ability to flex and resiliently return to an original conformation is not required of all panels in all implementations of the cladding systems described herein. One will appreciate, however, that resiliently flexible panels can be particularly useful when creating the shingle-style panels, which are partially lifted or bent in a particular corner, such as those shown in Figures IA- IB.

Furthermore, the panels 105 disclosed herein generally comprise panels of at least about six inches by about six inches (6" x 6") in width/height dimension. One will appreciate, however, that the size (i.e., surface area) of the panels 105 can also be any appropriate size for the resulting size of the final cladding system 100a/100b. In at least one implementation, for example, the panels 105 can be about can be about twelve inches by about twelve inches (12" x 12"), four feet by about eight feet (4' x 8'), about four feet by about ten feet (4' x 10'), about six feet by about fifteen feet (6' x 15'), or taller/wider. Furthermore, the panels 105 can be any appropriate thickness for the resulting thickness of a cladding system 100a/100b, such as about two inches (2"), about one inch (1"), about one-half inch (1/2"), about one-fourth inch (1/4"), about one-eighth inch (1/8"), about one-sixteenth inch (1/16"), or about one-thirty-second inch (1/32") in thickness or gauge as desired. Thus, both the gauge and size of the panels 105 can be tailored depending upon the desired dimensions of a cladding system 100a/100b. As mentioned previously, the panels 105 of the cladding structures of the present invention can be arranged or aligned in a shingle-style or overlapping formation. For example, Figure IA shows that each panel 105 of the cladding system 100a is configured to at least partially overlap at least a portion of an immediately adjacent panel 105, while another panel 105 overlaps in an adjacent position from above. In other words, each panel 105 (excluding the first row and first column of panels) is at least partially overlapped by one or more adjacent panels 105.

One will appreciate that the illustrated, overlapping alignment can provide a structure (e.g., outside or inside structure of a building, such as a wall, etc.) with a shielding functionality against outside elements, such as wind and rain/precipitation. In particular, the cladding system 100a/100b can prevent any wind or rain/precipitation from reaching the underlying structure because of the overlapping arrangement of the panels 105. In addition to shielding rain and wind, the cladding system 100a/100b can function to reflect heat from the sun away from the structure and thus help maintain a desired temperature within the structure. Furthermore, the cladding system 100a/100b also can function as an insulator and help retain hot or cold air within the interior of the structure.

In addition to arranging and aligning the panels in an overlapping shingle style, a manufacturer/assembler can place a hood or flashing around the outside edges of the cladding system. The flashing can be used to prevent rain, snow, and/or wind from reaching the underlying surface by entering along any edge panel. For example, a manufacturer/assembler can place flashing (not shown) around the upper and far left edges of the cladding system 100a depicted in Figure IA to ensure that the elements do not reach the underlying structure by entering along any edge panels 105(a, b, c, e, g, etc.). The flashing can be formed from a metal, such as aluminum, from the same material used to form the panels 105, or any other suitable material. Because the cladding system 100a provides an excellent barrier against the elements, it may be advantageously mounted to any type or portion of a support structure. For example, Figure IA shows that the cladding system 100a is mounted to a wall structure, such as an exterior wall of a pre-existing building. In addition to use as cladding on an exterior wall, the cladding system 100a can be secured to a roof, an awning, or other exterior features of a building. In addition, to use as a barrier on the exterior of a structure, cladding systems of the present invention can also be mounted on the interior surfaces of a building or other structure. For example, Figure IB illustrates that cladding system 100b is mounted to a ceiling structure. It is to be understood, however, a manufacturer/assembler can secure the cladding system 100b to a ceiling, floor, interior wall, or other features of the interior of a structure.

One will appreciate that when used to clad an interior surface of a building or other structure, the shingle-style formation of the cladding system 100b may not serve as a shield against the outdoor elements. Nonetheless, a manufacturer/assembler may desire to use a cladding system 100b within a building or other structure in order to create a desired aesthetic. For example, in the particular implementation shown in Figure IB, the overall resulting shape of each individual panel 105 extends into a plurality of dimensional spaces, so that each panel 105 appears on its face to be essentially three-dimensional and provides an aesthetic of depth. Furthermore, in addition to overlapping panels, cladding systems of the present invention can include panels with edges or corners that are flared or lifted to provide a desired aesthetic. For example, Figures 1A-1B show that a shingle-style formation can be formed not only from overlapping adjacent panels 105, but also from lifting one of the corners of the given panel 105 in an overlapping assembly (e.g., panel 105b with respect to panel 105a). Indeed, in some implementations a corner of each panel 105 can be lifted or flared away from the underlying structure to provide a unique aesthetic. For instance, Figure IA shows that each lower right corner of each given panel 105 is positioned on top of the lower right standoff component 120, thereby creating a "lift." In particular, this "lift" is created at least in part since the other remaining ends/corners/sides of each given panel 105 are positioned or otherwise affixed at a lower position on a given standoff component 120. Along these lines, Figure IB illustrates effectively the same cladding alignment on cladding system 100b, except an orientation in which the lower left corner of each given panel 105 is lifted or flared. In additional or alternative implementations, a manufacturer/assembler can add additional or alternative geometry or curvature to each panel 105 in order to provide a desired aesthetic. For instance, a manufacturer/assembler can flare or bend out both bottom corners of each panel 105. According to additional implementations of the present invention a manufacturer/assembler can form one or more of the panels 105 to include wave-like geometry. One will appreciate that one or more of the panels 105 can include various simple or complex geometries to achieve a desired aesthetic, in addition to providing the functional element-deflection benefits described herein.

In addition to varying the geometry of the panels 105, a manufacturer/assembler can vary the transparency and/or color of the panels to provide a desired aesthetic. For example, if the panels 105 forming the cladding structures 100a/100b illustrated in Figures IA- IB are opaque, the panels 105 will tend to hide or conceal the standoff components 120 from a facing view since each standoff component 120 is positioned behind a given resin-based panel 105. In such an implementation, the panels 105 may reduce the visibility of hardware (e.g., 120, 130) used to mount the panels to the pre-existing support structure.

In additional embodiments, however, the panels 105 can be transparent, translucent, and/or colored, as desired. When transparent or translucent panels 105 are used, the standoff components 120 can be at least partially visible through the panels 105 from a facing view. Furthermore, a manufacturer/assembler can form the panels 105 to include embedded two or three-dimensional objects such as thatch, willow reed, coffee beans, bamboo, and similar objects in order to provide a desired aesthetic. Thus, one will appreciate that a manufacturer/assembler create cladding systems using panels 105 including any number or combinations of different aesthetic features (e.g., color, transparency, surface texture, embedded objects, or printed images). Furthermore, a manufacturer/assembler can use a variety of panels each with similar or different aesthetic features to provide a desired overall aesthetic.

Referring again to the Figures, Figures 1A-1B show each panel 105 appears mounted to a support structure using a standoff component 120 at one or more corners of the given panel 105. In general, a "standoff component" comprises one or all of the various components used in a traditional standoff. For example, a conventional standoff comprises a standoff barrel that mounts directly to a frame or support structure, such as one or more brackets inserted in frame 130 (e.g., about fixed mounting point 115d). Many traditional standoffs also include a standoff cap that threads into the standoff barrel at an opposing end. The standoff cap typically includes a planar surface a corresponding threaded stem that a manufacturer can insert and/or secure within the standoff barrel.

Notably, a manufacturer can use any or all of these items in various combinations to secure a panel to a support structure. As used herein, Figure 2 shows that a standoff comprising a standoff barrel, cap, and stem that mounts directly into frame 130 (e.g., via one or more corresponding brackets) is labeled standoff component 120a. By contrast, Figure 2 shows that a standoff comprising a standoff cap and stem that mounts directly into frame 130 (e.g., via one or more corresponding brackets) is labeled standoff component 120b. For example, Figures IA and IB show that various edge panels (e.g., panels 105a, 105b, and 105e) comprise use of both of the standoff components 120a and 120b (labeled generally as 120) with a standoff barrel affixed at fewer than all of the possible corners. By contrast, the more interior panels (e.g., 105d, 105f) comprise a standoff component 120a affixed or otherwise present at all of the possible corners. In any event, Figures IA, IB, and 2 show that any given panel 105 will typically have a standoff component 120 affixed or otherwise present at a plurality of different corners, though this is not necessarily required.

By way of explanation, usage of the term "standoff component" is made by way of convenience in description to illustrate at least one type of securement component/member, or a component/member that can be used to secure (rigidly or flexibly) a portion (e.g., a given corner) of a panel 105 to a support structure (e.g., via frame 130). For example, the standoff components 120a and 120b need not necessarily be components only associated with traditional "standoffs," as such. In accordance with implementations of the present invention, for example, components 120a and 120b can include other types of securement components/members, including a wide range of types, shapes, sizes, or styles of fasteners, including virtually any threaded fasteners that can be used to secure (or otherwise prop away) a given panel 105 portion to or from a support structure (e.g., via frame 130).

Regardless of the number or type of possible standoff components 120a/b used to affix the panel 105 portions, each of the panels 105 in this particular implementation are only "rigidly affixed" to the frame 130 at one portion/corner by any particular standoff component 120. As used herein, the term "rigidly affixed" or "rigidly secured" means that the panel 105 has no degrees of freedom, or cannot move in any direction with respect to the standoff component 120 at that particular point. By contrast, Figures IA and IB show that each panel 105 is otherwise partly or "flexibly affixed" in a relatively loose fashion to the frame 130 with one or more additional standoff components 120 at one or more other corners. As used herein, the term "flexibly affixed" or "flexibly secured" means that the panel 105 has at least one degree of freedom, or can be moved in at least one direction relative to the standoff component 120. The mechanics for mounting the panels 105 in a cladding system with a single corner rigidly affixed using a standoff component 120 are described more fully below.

Figure 2 illustrates a schematic overview of the various parts and components a manufacturer/assembler can use to assemble a shingle-style cladding system 100a in accordance with an implementation of the present invention. As shown, each panel 105 comprises a plurality of flexible mounting points llOa/HOb, and at least one fixed mounting point 115. The flexible mounting points can be open slots 110a that extend to the end of the given panel 105 (e.g., a U-shaped formation), or can be an enclosed slot HOb (e.g., an enclosed oval-shaped perforation). For example, Figure 2 shows that open slots 110a extend from a point within the panel 105 to the edge of the panel 105, while the enclosed slots 110b tend to be completely enclosed perforations. A manufacturer/assembler can use the flexible mounting points 110a/b to flexibly affix or secure the corresponding corners of the panel 105 to the underlying structure (e.g., frame 130). In other words, each corner secured to the underlying structure using a flexible mounting point 110a/b has at least one degree of freedom because the corner of the panel 105 can move along the slot of the flexible mounting point 110a/b relative to its corresponding standoff component 120.

As mentioned previously, each flexible mounting point can provide a corresponding corner of a panel with at least one degree of freedom. For example, Figure 2 illustrates that flexible mounting points 110a/b provide a panel corner with a single degree of freedom, i.e., along the open or enclosed slot which forms the flexible mounting point 110a/b. One will appreciate, however, that a given flexible mounting point 110 can provide a panel corner with more than one degree of freedom. For instance, Figure 3 illustrates an alternative panel 105, which includes flexible mounting point HOd comprising a groove extending along an edge of and into the panel 105. One will appreciate that the flexible mounting point 11Od can provide a panel with at least two degrees of freedom, i.e., in the direction along the bottom edge of the panel 105 and the direction along the side edge of the panel 105. Thus, a manufacturer/assembler can form the flexible mounting points 110 so they provide one or more degrees of freedom, or allow for ease of assembly. For example, Figure 3 illustrates a flexible mounting point 110c comprising a combination of a groove and a slot that can enable a manufacturer/assembler to slide the flexible mounting point 110c around a standoff component with ease.

One will appreciate that, however configured in any particular implementation, each flexible mounting point 110 can accommodate a certain amount of expansion and contraction of each given panel 105. Thus, as the temperature of a given panel 105 is increased or decreased — and the panel 105 undergoes thermal expansion or contraction — the panel 105 can move relative to the standoff components 120 used to flexibly secure the panel 105 to a support structure. In particular, each panel 105 can slide or move with respect to the given standoff component 120 by the length of the respective slot or groove of each flexible mounting point 110. By enabling the panels 105 to move relative to the standoff components 120, the flexible mounting points 110 can ensure that standoff components 120 do not dig into the edges of the panels 105, or otherwise damage the panels 105 due to any thermal expansion/retraction of the panels 105. The ability to account for expansion and retraction of a panel 105 can be particularly useful when the panels 105 are used as part of a cladding system 100a/b mounted outdoors that can subjected to a wide range of temperatures and other weather elements during a given year. In contrast to the flexible mounting points 110, fixed mounting point 115 comprises a relatively small perforation for fixedly receiving an extension end of a standoff component 120. A manufacturer/assembler can use a fixed mounting point 115 to rigidly affix a corresponding corner of the panel 105 to a support structure. In other words, when a fixed mounting point 115 is used, the corresponding corner of the panel 105 is fixed in place in all directions.

Thus, a given corner of a panel can be secured, either flexibly or rigidly, to a given support structure using a standoff component. In some implementations, a given corner of a panel can be secured to a frame secured to a wall or other underlying structure. For example, Figures IA, IB, and 2 illustrate that the panels 105 are secured to a frame 130. One will appreciate, however, that a manufacturer/assembler can secure the panels 105 directly to a wall, ceiling, floor, or other underlying structure without use of a frame 130. Similarly, a manufacturer/assembler can secure the panels 105 to a support structure mounted to an underlying structure other than a frame 130. Referring to Figure 2, for example, a manufacturer/assembler can use a standoff component 120b to rigidly affix an end of a panel 105b to a frame 130 via fixed mounting point 115b and standoff component 120b. The manufacturer/assembler can also affix panel 105a to the frame 130 via fixed mounting point 115a and standoff component 120a. The manufacturer/assembler can then rotate or move the panel 105b into any number of different positions as appropriate in order to mount or otherwise slide the other flexible mounting points 110a about the other standoff components (e.g., 120a) used to affix other panels (e.g., 105a) at the mounting point 115a. The manufacturer/assembler can also position a lower right corner of panel 105b on top of standoff component 120a, which itself is inserted in this case into flexible mounting points HOb in panels 105c and 105a (and ultimately another fixed mounting point 115 in panel 105d behind the flexible mounting points 110b).

Since in this case the manufacturer/assembler secures an opposing lower corner of panel 105b via standoff component 120a and another slotted mounting point HOa, positioning the lower right corner essentially on top of standoff component 120a provides a sense of "lift" to that lower corner. Of course, were the manufacturer/assembler to remove the standoff component 120a (or use a standoff component with a reduced height, e.g., standoff component 120b, or create a slot in the panel 105b to secure the panel 105b to a lower position on standoff component 120a) in this particular implementation from the corner, the panel 105b would flex back to its original, essentially two-dimensional or flat configuration. Furthermore, the rigidity of the panel 105b material ensures that the panel 105b retains secure positioning over standoff component 120a without having to secure panel 105b from the outside at this corner. As a result, panel 105b is only rigidly affixed in one position (115b) via standoff component 120b, and is flexibly secured at flexible mounting points HOa via two other standoff components 120a/b. Additionally, the lifted corner provides a visual aesthetic resembling a "shingle."

In addition to providing a pleasing visual aesthetic, lifting a corner of each panel 105 can also increase the strength of each given panel 105. In particular, lifting a corner of each panel 105 flexes the panel 105 or compresses the panel 105. When the panel 105 is subjected to the compressive forces caused by lifting a corner of the panel 105, the panel's strength is increased in the sense that the panel 105 becomes more rigid, or less prone to additional flexion. Thus, when a corner of a panel 105 is lifted, the panel 105 is more rigid and thus less susceptible to being deflected by wind or other external forces. Lifting a corner of each panel 105, therefore, is one way of increasing the strength of the panel 105, and hence the overall facade, without increasing the panel's gauge. High-end architectural resin-based panels are relatively expensive, and their price is proportional to their gauge. Therefore, by lifting a corner of each panel 105 a manufacturer/assembler can greatly increase the strength and aesthetics of a cladding system 100a/b at a substantial savings when compared with the alternative of increasing the panel gauge.

Figure 2 also illustrates how a manufacturer/assembler can overlap the plurality of panels 105 to form a shingle-style arrangement according to an implementation of the present invention. For example, Figure 2 illustrates that a manufacturer/assembler can rigidly affix or secure each panel 105 to a support surface at a fixed mounting point 115. Furthermore, a manufacturer/assembler can flexibly secure a second and a third corner of each panel 105 to the support surface at flexible mounting points 110. As shown in Figure 2, a manufacturer/assembler can flexibly secure each of the second and third corners above a corner of one or more adjacent panels.

For example, a manufacturer/assembler can flexibly secure the upper right corner of panel 105b to the frame 130 at flexible mounting point 110a directly above the upper left corner of panel 105 a that has been rigidly affixed to the support structure. Similarly, a manufacturer/assembler can flexibly secure the lower left corner of panel 105d to the support structure at flexible mounting point HOb directly above both the flexibly- secured upper right corner of panel 105g and the rigidly secured upper left corner of panel 105h. Finally, a manufacturer/assembler can prop or lift a fourth corner away from the support surface. For instance, as shown in Figure 2, a manufacturer/assembler can lift the lower right corner of panel 105b away from the support structure and rest it against standoff component 120a, which comprises the more elongate standoff barrel.

One will appreciate that the overlapping of each panel 105 will depend on its position within the cladding system 100a. For example, Figures 2 and IA illustrate that the various edges of a center panel, such as panel 105d shown in Figure IA, will each either at least partially overlap or partially be overlapped by the edges or corners of the surrounding eight panels 105a, 105b, 105c, 105e, 105f, 105g, 105h, 105i. In particular, a manufacturer/assembler can rigidly affix the upper left corner of panel 105d to the frame 130, and overlap it with at least the corners of the three adjacent panels 105a, 105c, 105b. The manufacturer/assembler can then overlap the lower edge of center panel 105d over panel 105h, and flexibly secure the lower left corner of center panel 105d to a standoff component 120 directly on top of or above the upper right corner of panel 105g and the upper left corner of panel 105h. The manufacturer/assembler can then overlap the lower left corner of panel 105d with at least the corner of the adjacent panel 105c. Similarly, a manufacturer/assembler can overlap the right edge of center panel

105d over at least over the edge of adjacent panel 105f. Then the manufacturer/assembler can flexibly secure the upper right corner of panel 105d directly on top of or above the upper left corner of panel 105f. After which, the manufacturer/assembler can overlap the upper right corner of panel 105d with at least the lower left corner of panel 105e and the lower right corner of panel 105a. Finally, the manufacturer/assembler can lift the lower right corner of panel 105d and prop it against a standoff component 120(a) so that it at overlaps at least the corners of adjacent panels 105h, 105f, 105L

In summary, once a manufacturer/assembler has completely secured all relevant corners (e.g., four in this case) of the center panel 105d, the corners of panel 105d will each either at least partially overlap or partially be overlapped by the edges or corners of the surrounding other illustrated panels 105a, 105b, 105c, 105e, 105f, 105g, 105h, 105i. In the particularly illustrated case, for example, the center panel 105d will overlap four adjacent panels at least once and will be overlapped at least once by four additional adjacent panels, etc. For instance, Figure 2 shows that the rigidly- affixed first corner or upper left corner of panel 105d will be overlapped by at least one corner of three adjacent panels 105a, 105c, 105b. A flexibly- secured second corner or upper right corner will overlap at least one rigidly secured corner of an adjacent panel 105f, and be overlapped by at least one corner of two adjacent panels 105a, 105e. A flexibly- secured third corner or lower left corner will overlap at least one rigidly affixed corner of adjacent panel 105h and one flexibly secured corner of adjacent panel 105g. The third corner of panel 105d can also be overlapped by at least a corner of an adjacent panel 105c, which in Figure 2 has been lifted. Finally, a fourth corner or lower right corner can be lifted and overlap at least one corner of the three adjacent panels 105f, 105h, 105L

One will appreciate that the overlapping of panels 105 will be reduced for any edge panels, such as panels 105a, 105b, 105c, 105e, 105g shown in Figure IA. For example, Figure IA illustrates that panel 105b is not overlapped by any adjacent panels. Figure IA illustrates, however, that panel 105b does overlap the adjacent panels 105a, 105c, and 105d. Thus, one will appreciate that while a center panel will overlap or be overlapped by eight adjacent panels; the overlapping of an edge panel will be reduced depending upon its position and the number of panels adjacent thereto.

Figure 4 illustrates a side-cross sectional view of a joint 140 of the cladding system 100a of Figure IA taken along the line 4-4 shown in Figure IA. Figure 4 illustrates that the joint 140 can be used to join a plurality of panels in a shingle-style formation. In particular, Figure 4 illustrates the joint 140 joins or otherwise combines at least a portion panels 105a, 105b, 105c, and 105d together. In particular, Figure 4 illustrates that a manufacturer/assembler can secure the proximal end 142 of the standoff component 120a to a frame 130, which is in turn secured to an underlying support structure (i.e., a wall, floor, ceiling etc.) As used herein, the terms "proximal" or "proximate" and "distal" or "distant" are in reference to any underlying support structure to which a cladding system is mounted. Therefore, the proximal end 142 of the standoff component 120a shown in Figure 4 is the end secured to the underlying support structure via the frame 130. On the other hand, the distal end 144 of the standoff component 120a is the end extending away from the support structure upon which a portion (e.g., lower right corner) of panel 105b is propped.

As shown, standoff component 120a flexibly secures panel 105a to the support structure by engaging the flexible mounting point HOa. Similarly, standoff component 120a flexibly secures panel 105c by engaging a flexible mounting point 110b. By contrast, standoff component 120a rigidly affixes panel 105d at its corresponding fixed mounting point 115d. Panel 105b, in turn, is positioned so that at least a portion (e.g., the lower right corner) is lifted over and rested upon the distal end 144 of standoff component 120a, thereby creating one of the aesthetic elements of the particularly illustrated shingle-style.

Each joint 140, and therefore each standoff component 120, of a cladding structure can be used to join multiple panels at the same time. For example, Figure 4 illustrates that joint 140 can rigidly affix a base panel 105d to an underlying structure via a frame 130 using a standoff component 120a. As discussed previously, a panel is rigidly affixed when it is constrained in all directions, or has no degrees of freedom. Directly over or upon the base panel 105d, the joint 140 can flexibly secure one or more additional panels. For instance, Figure 4 illustrates that joint 140, using standoff component 120a, flexibly secures panels 105c, 105a directly over rigidly secured base panel 105d. The panels 105c, 105a are flexibly secured to the joint 140 because they have at least one degree of freedom, i.e., the panels 105c, 105a can move relative to the joint 140 and the standoff component 120a along their slots, grooves, or perforations forming the flexible mounting points 110a/b.

One will appreciate that a manufacturer/assembler can increase or decrease the lift of panel 105b by increasing or decreasing the length of the standoff component 120a. According to some implementations of the present invention, a manufacturer/assembler can use a plurality of standoff components 120 of equal length. Alternatively, a manufacturer/assembler can use a plurality of standoff components (e.g., various standoff barrels) of various lengths, and thus, panels lifted to various heights in order to create a desired aesthetic. Furthermore, according to some implementations of the present invention, a manufacturer/assembler can secure the panel 105b directly against panel 105c, such that the panel 105b has no lift (e.g., using only standoff component 120b).

Accordingly, one will appreciate that at least one feature of the present invention is that multiple corners of different panels can be secured, whether in a flexible or rigid manner, using a single standoff component. For example, Figure 4 shows that the corners of panels 105a, 105c, and 105d are overlapped and secured underneath standoff component 120a, while panel 105b is positioned on top of standoff component 120a. In such a case, standoff component 120a helps maintain panel 105b in place due primarily to frictional and/or deflection type forces. In any event, one will appreciate that this ability to secure multiple different panel corners with a single standoff component allows a manufacturer/assembler to minimize the amount of mounting hardware (e.g., standoff components) otherwise needed. That is, rather than needing to secure each corner of multiple different panels with multiple different standoff components a piece (e.g., 16 total standoff components for 4 different panels), a manufacturer/assembler can secure 4 different panels in a shingle- style formation using as many (or as few) as 9 different standoff components. As such, one or more implementations of the present invention provide certain cost savings at the very least.

The present invention also includes methods of assembling and securing panels as a cladding system or facade to a support structure. The following describes at least one implementation of a method of mounting a plurality of panels 105 about a pre-existing structure to create a weather resistant, aesthetically pleasing cladding system, such as shown in Figures IA, 2, and 4. Of course, as a preliminary matter, one of ordinary skill in the art will recognize that the methods explained in detail can be modified to install a wide variety of cladding systems to a wide variety of support structures according to one or more implementations of the present invention.

For example, at least one method of the present invention comprises an act of rigidly affixing a first panel to pre-existing structure with a standoff component. For example, a manufacturer/assembler rigidly affixes a first panel 105d to a pre-existing structure using a standoff component 120a. In particular, the manufacturer/assembler can insert a proximal end 142 of the standoff component 120a through a fixed mounting point 115d and secure it within a frame 130.

The method can also include flexibly affixing a second panel to the structure with the standoff component, such that at least a portion of the second panel overlaps the first panel. For example, a manufacturer/assembler flexibly affixes a second panel 99

105c to the support structure (e.g., via frame 130) using the standoff component 120a. In particular, the manufacturer/assembler can overlap at least a portion of the second panel 105c over the left edge of the first panel 105d and flexibly secure the upper right corner of the second panel 105c directly above and against the first panel 105d using the standoff component 120a. To accomplish this, the manufacturer/assembler can rotate and otherwise orient the second panel 105c to allow the standoff component 120a to be slid within the slot and/or groove of the flexible mounting point 110 formed in panel 105c.

In addition, the method can include flexibly affixing a third panel to the standoff component such that at least a portion of the third panel overlaps the first panel and the second panel. For example, in addition to the above, the manufacturer/assembler can flexibly affix a third panel 105a to the structure in a manner that at least a portion of the third panel 105a overlaps the first panel 105d and the second panel 105c. In particular, the manufacturer/assembler can overlap at least a portion of the third panel 105a over the upper edge of the second panel 105c and over the upper edge of the first panel 105d. The manufacturer/assembler can then flexibly secure the lower left corner of the third panel 105a directly above and against the second panel 105c using the standoff component 120a. In particular, the manufacturer/assembler can orient and rotate the third panel 105a to allow the standoff component 120a to be slid within the slot and/or groove of the flexible mounting point 110 formed in the third panel 105a.

Furthermore, the method can include positioning a fourth panel over the standoff component such that at least a portion of the fourth panel overlaps the first panel, the second panel, and the third panel. For example, having secured the standoff component 120a through the first panel 105d, the second panel 105c, and the third panel 105 a, the manufacturer/assembler can tighten the standoff component 120a within the frame 130. The manufacturer/assembler can then position a fourth panel 105b over the standoff component 120a by lifting a portion of the fourth panel 105b over and resting it against the standoff component 120a. The manufacturer/assembler can position the fourth panel 105b such that it at least partially overlaps the right edge of the third panel 105a and the upper edges of the first and second panels 105c, 105d to create a shingle-style configuration.

One will appreciate that implementations of the present invention can also be applied broadly with several different types of alterations within the scope of the present invention for yet additional advantages. For example, the standoff components disclosed herein can be varied in terms of gauge and height to thereby affect the "lift" aesthetic of a given panel orientation, or to otherwise minimize exposure of the standoff component. In addition, the standoff components disclosed herein can be modified to include any number of soft or rubberized top surfaces to minimize noise or damage that could occur if a given panel corner at a "lift" position were to move for any reason and rub or tap/bang against the standoff component, e.g., during extreme weather.

The present invention may thus be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A cladding system for cladding a pre-existing structure with weather- resistant, panels, comprising: a plurality of panels, including a base panel and plurality of overlapping panels that at least partially overlap the base panel to form a weather resistant facade for the pre-existing structure; and a standoff component attached to the base panel at a plurality of corners; wherein: at least one standoff component rigidly affixes a first corner of the base panel to the pre-existing structure; and the at least one standoff component flexibly affixes one or more overlapping panels to the base panel and to the pre-existing structure.

2. The cladding system as recited in claim 1, wherein the plurality of panels comprises resin-based panels that are at least as large as twelve inches by twelve inches.

3. The cladding system as recited in claim 1, wherein a distal end of the at least one standoff component supports and rests against a lifted corner of an additional panel.

4. The cladding system as recited in claim 3, wherein the standoff components used at the plurality of corners comprise a standoff cap used in one corner and a standoff barrel used in one or more of the other corners of the plurality.

5. The cladding system as recited in claim 3, wherein the standoff components used at the plurality of corners comprise a standoff barrel used in one corner and a standoff cap used in one or more of the other corners of the plurality.

6. The cladding system as recited in claim 3, wherein the distal end of the at least one standoff component comprises a rubber surface for dampening vibrations.

7. The cladding system as recited in claim 3, wherein the plurality of panels are arranged to create a shingle- style aesthetic.

8. The cladding system as recited in claim 1, wherein the at least one standoff component extends through a flexible mounting point formed in the one or more overlapping panels.

9. The cladding system as recited in claim 8, wherein the flexible mounting point comprises an enclosed slot extending through the one or more overlapping panels.

10. A cladding system for cladding a support structure with a plurality of resin- based panels, comprising: a plurality of resin-based panels mounted to a support structure as a decorative and functional facade for the support structure; wherein, for each resin-based panel: at least one corner is rigidly secured to the support surface; at least a second corner is flexibly secured to the support surface and above a rigidly secured corner of another panel; and at least a third corner is propped away from the support surface.

11. The cladding system as recited in claim 10, wherein at least a fourth corner of the resin-based panel is flexibly secured to the support surface directly above a rigidly secured corner of an adjacent panel.

12. The cladding system as recited in claim 10, wherein a corner of an additional panel is flexibly secured to the support surface between the at least a second corner and the rigidly secured corner of the another panel.

13. The cladding system as recited in claim 10, wherein the at least a second corner comprises a flexible mounting point.

14. The cladding system as recited in claim 13, wherein the flexible mounting point comprises a groove extending a distance along an edge of the panel and extending a distance into the resin-based panel.

15. The cladding system as recited in claim 10, wherein the resin-based panel partially overlaps four panels.

16. The cladding system as recited in claim 15, wherein the resin-based panel is partially overlapped by four additional panels.

17. The cladding system as recited in claim 10, wherein: the support structure comprises one of an exterior wall of a building; and the plurality of resin-based panels comprise a precipitation barrier to the exterior wall.

18. In an architectural design environment comprising a pre-existing structure and a plurality of panels configured to be mounted about the pre-existing structure, a method of mounting the plurality of panels about the pre-existing structure to create a weather resistant, aesthetically pleasing cladding, comprising the acts of: rigidly affixing a first panel to the pre-existing structure with a standoff component; flexibly affixing a second panel to the structure with the standoff component, such that at least a portion of the second panel overlaps the first panel; flexibly affixing a third panel to the standoff component such that at least a portion of the third panel overlaps the first panel and the second panel; and positioning a fourth panel over the standoff component such that at least a portion of the fourth panel overlaps the first panel, the second panel, and the third panel.

19. The method as recited in claim 18, wherein the act of positioning the fourth panel over the standoff component further comprises lifting a portion of the fourth panel away from the pre-existing structure.

20. The method as recited in claim 18, wherein the act of flexibly affixing a second panel to the structure with the standoff component further comprises rotating a groove formed in the second panel around the standoff component.