US006427409B2
`(10) Patent No.:
`a2) United States Patent
`US 6,427,409 B2
`Colson et al.
`(45) Date of Patent:
`Aug.6, 2002
`
`
`(54) CLADDING SYSTEM AND PANEL FOR USE
`IN SUCH SYSTEM
`
`(75)
`
`Inventors: Wendell B. Colson, Boulder; Lee A.
`Cole, Evergreen; Jason T. Throne,
`Steamboat Spgs, all of CO (US)
`
`:
`
`.
`
`(73) Assignee: Hunterrue Inc., Upper Saddle
`
`(*) Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`US.C. 154(b) by 0 days.
`(21) Appl. No.: 09/783,238
`.
`(22)
`Filed:
`Feb. 14, 2001
`
`Related U.S. Application Data
`
`(62) Division of application No. 08/752,957, filed on Nov. 20,
`1996. now Pat. No. 6.199.337.
`,
`_
`Int. C17eee E04F 13/00; E04B 9/00
`(S51)
`(52) US. Ch. cic ceccccce cesses 52/506.08; 52/506.07;
`52/508; 160/84.05
`(58) Field of Search .....0.0. 52/506.06, 506.07,
`52/508, 511, 6, 63, 71, 222, 2.24, 2.22,
`202, 203; 160/84.01, 84.03, 84.05, 84.08,
`348
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
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`(List continued on next page.)
`}
`;
`Primary Examiner—Robert Canfield
`(74) Attorney, Agent, or Firm—Dorsey & Whitney LLP
`57
`ABSTRACT
`e7
`A cladding system for walls or ceilings of a building
`structure consisting of a panel or panels that are sectioned so
`as to provide a variety of aesthetics. The sections in the panel
`may be joined along articulated lines of joinder so that an
`entire panel comprised of a plurality of sections can be
`expanded orretracted to either cover or selectively expose
`the wall or ceiling across which the system is mounted. The
`sections in a panel may be cellular and may thereby form a
`honeycomb-type panel, and the materials from which the
`panels are made may vary between being rigid, flexible,
`hard, soft,
`flat, reflective, and the like. Panels can be
`supported with side rails extending along each side of the
`panel while not requiring cross rails so that, for example,
`when a panel is used in a ceiling system and retracted from
`its expanded condition beneath a ceiling structure, generous
`accessis provided to theceiling structure for repair or other
`work on utilities such as plumbing,electrical, and the like
`that are found embedded in the ceiling. Intermediate rails,
`parallel to the side rails, can also be provided, if necessary,
`to support a panel along intermediate portions thereof or
`between adjacent panels. The supporting rails for the panels
`can take on numerous configurations so as to support the
`.
`.
`.
`panels in varied ways depending to some degree upon the
`particular panel construction being utilized.
`
`10 Claims, 50 Drawing Sheets
`
`Petitioner Chanel, Inc. Exhibit 1026
`Page 1
`
`Petitioner Chanel, Inc. Exhibit 1026
`Page 1
`
`

`

`US 6,427,409 B2
` Page 2
`
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`FOREIGN PATENT DOCUMENTS
`
`Petitioner Chanel, Inc. Exhibit 1026
`Page 2
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`Petitioner Chanel, Inc. Exhibit 1026
`Page 2
`
`

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`U.S. Patent
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`Aug. 6, 2002
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`US 6,427,409 B2
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`Aug. 6, 2002
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`Aug. 6, 2002
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`Petitioner Chanel, Inc. Exhibit 1026
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`U.S. Patent
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`Aug. 6, 2002
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`Sheet 47 of 50
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`U.S. Patent
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`Aug. 6, 2002
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`Sheet 48 of 50
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`US 6,427,409 B2
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`U.S. Patent
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`Aug. 6, 2002
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`Sheet 49 of 50
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`US 6,427,409 B2
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`Petitioner Chanel, Inc. Exhibit 1026
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`U.S. Patent
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`Aug. 6, 2002
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`Sheet 50 of 50
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`US 6,427,409 B2
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`Petitioner Chanel, Inc. Exhibit 1026
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`US 6,427,409 B2
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`1
`CLADDING SYSTEM AND PANEL FOR USE
`IN SUCH SYSTEM
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`This application is a division of U.S. patent application
`Ser. No. 08/752,957, filed Nov. 20, 1996, now U.S. Pat. No.
`6,199,337, which claims benefit of U.S. provisional appli-
`cation No. 60/007,501, filed Nov. 22, 1995. These applica-
`tions are hereby incorporated by reference as though fully
`set forth herein.
`
`BACKGROUND OF THE INVENTION
`
`1. Field of the Invention
`
`The present invention relates generally to cladding sys-
`tems and more particularly to ceiling systems and wall
`coverings for building structures. The system may be a
`sectional or in some instances cellular system and can in
`some embodiments be expanded and retracted across a wall
`or an overlying ceiling structure.
`2. Description of the Known Art
`Ceilings or walls for building structures take many dif-
`ferent forms that can be as basic as wood panels or drywall
`to,
`in the case of ceilings, more elaborate designer-type
`ceilings. Designer-type ceilings may consist of metal or
`plastic tubes, strips, panels, sheets of fabric or the like,
`which are interconnected in various forms and configura-
`tions to obtain a desired aesthetic effect. Such designer
`systems are typically reserved for commercial establish-
`ments. Between the two above-noted extremes are ceiling
`systems commonlyreferred to as drop ceilings which incor-
`porate a grid work of interconnected metal support strips
`defining shelves on which insulating panels are removably
`seated. Such systems are commonly found in both commer-
`cial and residential establishments and are desirable for
`
`many reasons which include aesthetics, sound absorption,
`heat insulation and the fact that the panels are removable to
`access the ceiling structure abovethe ceiling system and any
`utilities such as plumbing, ventilation or electrical that may
`be found above the ceiling system.
`Drywall ceilings, while being one of the most common
`ceilings found in building structures, have the drawback of
`being very inflexible and also very plain from an aesthetic
`standpoint. In order to access the space above a drywall
`ceiling, holes must be cut in the drywall or the drywallitself
`removed which can be an expensive process considering
`replacement. The designer-type systems are also more per-
`manentin nature even though providing a greater variety of
`aesthetics but have the drawback of being difficult and
`accordingly expensive to remove and replace in order to
`repair plumbing,electrical or other such utilities that might
`be found in the ceiling structure.
`Drop ceilings have the advantage of providing accessi-
`bility to the space thereabove but are very limited from an
`aesthetic standpoint and further, access to the space above
`the drop ceiling is only available through relatively small
`openings providedin the supporting grid work of the system.
`It is to overcome the shortcomings in prior art ceiling
`systems that the present invention has been developed.
`SUMMARYOF THE INVENTION
`
`The cladding system of the present invention consists of
`a panel or panels that are sectional so as to provide a variety
`of aesthetics. The sections in the panels may be joined along
`articulated lines of joinder so that an entire panel comprised
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`of a plurality of sections can be expanded orretracted to
`either cover or selectively expose a wall or an overlying
`ceiling structure. The sections in a panel may be cellular and
`may thereby form a honeycomb-type panel and the materials
`from which the panels are made may vary between being
`rigid, flexible, hard,soft, flat, reflective and the like. It will,
`therefore, be appreciated that various aesthetics can be
`obtained by varying the structure of the sections or through
`the materials from which the panels are made.
`The panels can be supported with side rails extending
`along each side of the panel while not requiring crossrails so
`that when a panelis used in a ceiling system and retracted
`from its expanded condition beneath a ceiling structure,
`generous access is providedto the ceiling structure for repair
`or other work on utilities such as plumbing,electrical and
`the like that are found embedded in ceiling structures.
`Intermediate rails, parallel to the side rails, can also be
`provided, if necessary, to support a panel along intermediate
`portions thereof or between adjacent panels. The supporting
`rails for the panels can take on numerous configurations so
`as to support the panels in varied ways depending to some
`degree upon the particular panel construction being utilized.
`Other aspects,features and details of the present invention
`can be more completely understood by reference to the
`following detailed description of preferred embodiments,
`taken in conjunction with the drawings.
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a perspective view of a building structure having
`a first embodiment of the present invention installed as a
`ceiling panel therein.
`FIG. 2 is an enlarged transverse section through onecell
`used in the ceiling panel of FIG. 1.
`FIG. 3 is a transverse section taken through a plurality of
`interconnected cells of the type shown in FIG. 2.
`FIG. 4 is a section taken adjacent to one side edge of a
`ceiling panel made out of interconnected cells as shown in
`FIG. 3 with the panel being supported by an undulating side
`rail.
`
`FIG. 5 is an isometric view of the ceiling panel of FIG. 4.
`FIG. 6 is an isometric view from the underside of the
`
`panel shown in FIG. 5.
`FIG. 7 is a transverse section taken through a cell used in
`a second arrangement of a cellular ceiling panel in accor-
`dance with the present invention.
`FIG. 8 is a transverse section taken through a plurality of
`interconnected panels of the type shown in FIG. 7.
`FIG. 9 is a fragmentary isometric of the end of a cellular
`ceiling panel wherein the cells have been perforated and
`slotted at the end to receive a support rail.
`FIG. 10 is a transverse section taken through a plurality of
`interconnected cells of a cellular ceiling panel in accordance
`with the present invention wherein the cells have an insu-
`lating or sound absorptive material therein.
`FIG. 11 is a transverse section similar to FIG. 10 wherein
`
`thereby compressing the
`the cells have been collapsed,
`insulative or sound absorptive material therein.
`FIG. 12 is an isometric of a ceiling panel of the type
`shown in FIG. 1, showing the side edges of the panel
`supported on side rails.
`FIG. 13A is a longitudinal section taken adjacentto a side
`rail showing a magnetic system for securing the ceiling
`panel to an endrail.
`FIG. 13B is a longitudinal section similar to FIG. 13A
`showing a mechanical system for interconnectingthe ceiling
`panel to an endrail.
`
`Petitioner Chanel, Inc. Exhibit 1026
`Page 53
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`Petitioner Chanel, Inc. Exhibit 1026
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`US 6,427,409 B2
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`3
`FIG. 14 is an isometric showing a ceiling panelof the type
`illustrated in FIG. 1, with side rails supporting side edges of
`the panel and a center support bar wherein the panel is in a
`collapsed position.
`FIG. 15 is an isometric of the ceiling panel of FIG. 1, as
`viewed from beneath the panel.
`FIG. 16 is an isometric similar to FIG. 15 viewed from
`above the panel.
`FIG. 17 is a longitudinal section taken through a ceiling
`panelutilizing an alternative arrangementfor a side support
`rail.
`
`FIG. 18 is a section taken along line 18—18of FIG. 17.
`FIG. 19 is a longitudinal section through a panel of the
`type shown in FIG. 1, showing another alternative arrange-
`ment of a side support rail.
`FIG. 20 is a section taken along line 20—20of FIG. 19.
`FIG. 21 is a longitudinal section through a panel of the
`type shown in FIG. 1 showing still another alternative
`arrangementof a side support rail.
`FIG. 22 is a section taken along line 22—22 of FIG. 21.
`FIG. 23 is a transverse section taken through a first
`arrangement of an intermediate support rail for supporting
`adjacent sides of two adjacent ceiling panels of the present
`invention.
`
`FIG. 24 is a transverse section similar to FIG. 23, showing
`another alternative arrangement of an intermediate support.
`FIG. 25is a transverse section similar to FIG. 23, showing
`still another intermediate support rail.
`FIG. 26 is a transverse section similar to FIG. 23, showing
`still another intermediate support rail.
`FIG. 27is an isometric view of one end of a cellular panel
`of the type shown in FIG. 1, wherein the sides of the panel
`have been notched to receive a side rail of the type shown
`in FIG. 17.
`
`FIG. 28 is a fragmentary isometric of a panel of the type
`shown in FIG. 1, wherein the sides of the panel have been
`slotted to receive a side rail of the type shown in FIG. 17 and
`a center rail of inverted T-shaped configuration.
`FIG. 28Ais a fragmentary isometric showing one end of
`a cellular panel of the type shown in FIG. 1, with the side of
`the panel having beenslotted to receive a siderail of the type
`shown in FIG. 14.
`FIG. 29 is an isometric of a second embodiment of the
`present invention, referred to as a soft cell embodiment, as
`viewed from beneath the panel mounted on a ceiling struc-
`ture.
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`FIG. 38 is a view similar to FIG. 37 showing another
`arrangement for supporting a pleat of a panel of the type
`shown in FIG. 29.
`
`FIG. 39 is a view similar to FIG. 37 showingstill another
`system for supporting a pleat in a panel.
`FIG. 40 is a view similar to FIG. 37 showingstill another
`system for supporting a pleat in a panel.
`FIG. 41A is a fragmentary transverse section showing a
`support in still another system for supporting a pleat in a
`panel, with the pleat having only been partially inserted into
`the support.
`FIG. 41B is a section similar to FIG. 41A wherein the
`
`pleat is fully inserted into the support.
`FIG. 42Ais an isometric showingstill another system for
`supporting a pleat in a panel.
`FIG. 42Bis a view similar to FIG. 42A showinga pleated
`portion of material connected to the support shown in FIG.
`42A.
`
`FIG. 43 is an isometric of a pleated facing sheet of
`material used in an alternative arrangementofthe soft cell
`embodiment of the present invention.
`FIG. 44 is a fragmentary isometric similar to FIG. 43
`showing a pleated backing sheet of material used in com-
`bination with the facing sheet illustrated in FIG. 43 to form
`an alternative arrangement of the soft cell embodiment of
`the present invention.
`FIG. 45 is a fragmentary isometric showing the sheets of
`material illustrated in FIGS. 43 and 44 interconnected into
`
`the alternative arrangement of the soft cell embodiment.
`FIG. 46 is a fragmentary exploded section illustrating a
`system for joining twostrips of material to form a soft cell
`arrangementof the present invention.
`FIG. 47 is a view similar to FIG. 46 with the components
`interconnected to form the associated soft cell arrangement.
`FIG. 48 is a section similar to FIG. 47 showing an
`alternative system for joining two adjacentstrips of material
`into a soft cell arrangement of the invention.
`FIG. 49 is an enlarged fragmentary section showingstill
`another system for supporting a pleat in a soft cell arrange-
`ment of the present invention.
`FIG. 50 is an enlarged fragmentary isometric of the
`system shown in FIG. 49.
`FIG. 51 is a fragmentary transverse section of anothersoft
`cell arrangement of the present invention.
`FIG. 52 is a fragmentary section similar to FIG. 51
`showing the lower sheet of the panel in varied sagging
`conditions.
`
`FIG. 30 is a fragmentary transverse section taken through
`the ceiling panel shownin FIG. 29.
`FIG. 31 is an isometric showing the ceiling panel of FIG.
`29 from the convex side thereof.
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`FIG. 53 is an enlarged fragmentary isometric showing a
`pleat of the arrangement shown in FIG. 51.
`FIG. 54 is a section taken along line 54—54 of FIG. 53.
`FIG. 32 is an isometric similar to FIG. 31 showing the
`FIG. 55Ais a transverse section taken through a pair of
`ceiling panel of FIG. 29 from the concave side thereof.
`interconnected strips of material which can be used to form
`a cell of a soft celled ceiling panel.
`FIG. 33 is a fragmentary transverse section similar to FIG.
`30 wherein the panel has been drawntaut.
`FIG. 55Bis a transverse section of an alternative system
`for forming a cell for a soft celled ceiling panel wherein the
`FIG. 34 is an enlarged fragmentary section, showing a
`cell is made from a single strip of material folded uponitself.
`pleat in the ceiling panel of FIG. 29.
`FIG. 56is a transverse sectionofstill another arrangement
`FIG. 35 is an enlarged fragmentary isometric showing the
`60
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`side of a pleat of the panel of FIG. 29, having been slotted for forming a cell whereinastrip of material as illustrated in
`to receive a side rail positioned adjacent thereto.
`FIG. 55 hasrigid auxiliary strips bondedto a surface thereof.
`FIG. 57 is a transverse section similar to FIG. 56 wherein
`FIG. 36 is a fragmentary isometric of a pleat of the panel
`shown in FIG. 29 wherein a supportbaris positioned within
`the ends of the strip have been preliminarily folded in a
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`the pleat as an alternative arrangement. process to formacell.
`65
`FIG. 58 is a transverse section similar to FIG. 57 wherein
`FIG. 37 is a fragmentary transverse section illustrating an
`alternative system for supporting a pleat in a ceiling panel of
`the strip has been additionally folded so as to define a
`the type shown in FIG. 29.
`double-walled cell with one sagging side.
`
`Petitioner Chanel, Inc. Exhibit 1026
`Page 54
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`Petitioner Chanel, Inc. Exhibit 1026
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`US 6,427,409 B2
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`6
`FIG. 79 is a fragmentary isometric showinga side rail for
`supporting the panel of FIG. 70 with portions of the panel
`being shown in dashedlines.
`FIG. 80 is a fragmentary transverse section showing the
`side support rails at opposite sides of a panel of the type
`illustrated in FIG. 70.
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`5
`FIG. 59 is a fragmentary section of a soft-celled ceiling
`panel of the type illustrated in FIG. 51 wherein the cell has
`been filled with an insulating or sound-absorbing material.
`FIG. 60 is a view similar to FIG. 59 but wherein a
`sprinkler head for a fire extinguishing system has been
`positioned within the cell where the lower material has an
`open cell structure.
`FIG. 81 is a side elevation showing the side rail of FIG.
`FIG. 61 is an isometric looking down on a double-walled
`79 in a vertically expanded condition.
`soft celled panel arrangement whereinaflat backing sheetis
`FIG. 82 is a sectional view similar to FIG. 81 again
`10
`bonded to upstanding pleats of a lower facing sheet.
`showing a side rail in a vertically expanded condition.
`FIG. 62 is an isometric view similar to FIG. 61 wherein
`FIG. 83 is a sectional view similar to FIG. 80 with the side
`rail in a retracted condition.
`FIG. 84 is a view similar to FIG. 81 wherein the side rail
`is in a retracted condition.
`FIG. 85 is a view similar to FIG. 82 wherein the side rail
`
`the top-backing sheet has been placed with elongated strips
`of backing material.
`FIG. 63 is an isometric similar to FIG. 62 wherein the
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`strips of backing material have been replaced with elongated
`cords.
`
`FIG. 64 is a section taken along line 64—64 of FIG. 63.
`FIG. 65 is a section taken through a cell in a further
`embodimentof the present invention referred to as a strip
`soft cell embodiment.
`
`FIG. 66 is a cross-section taken through a rigid piece of
`materialutilized to anchor adjacent side edgesofcells of the
`type shown in FIG. 65 to an existing hard surface.
`FIG. 67 is a fragmentary isometric of the strip shown in
`FIG. 66.
`
`FIG. 68 is a longitudinal section taken through a panel
`made with the components illustrated in FIGS. 65-67 con-
`nected to a supporting structure, wherein the panel is made
`from a plurality of cells of the type shown in FIG. 65.
`FIG. 69 is a perspective view of the ceiling of a room
`having a compressive triangle panel embodiment of the
`present invention.
`FIG. 70 is a fragmentary section taken along line 70—70
`of FIG. 69.
`
`FIG. 71 is a fragmentary section showing the intercon-
`nection of the lower side edges of rigid strips used in the
`panel of FIG. 70.
`FIG. 72 is a fragmentary section showing the intercon-
`nection of the upper edges of the rigid strips used in the
`panel of FIG. 70.
`FIG. 73 is a view similar to FIG. 71 showing an alterna-
`tive system for interconnecting the lower edges of the rigid
`strips.
`FIG. 73A is a view similar to FIG. 71 showing another
`alternative system for interconnecting the lower edgesof the
`rigid strips.
`FIG. 73B is a view similar to FIG. 71 showing still
`another system of connecting the lower edges of the rigid
`strips.
`FIG. 74 is a fragmentary longitudinal section through the
`panel of FIG. 70 showing compression and tension arrows
`in the various components of a cell of the panel.
`FIG. 75 is a fragmentary side view of a portion of the
`panel of FIG. 70 in a collapsed condition with the top
`backing sheet having been collapsed into the space between
`tworigid strips.
`FIG. 76 is a view similar to FIG. 75 wherein the top
`backing sheet has been pleated so that upon folding as
`illustrated the top backing sheet folds upwardly away from
`the rigid strips.
`FIG. 77 is a fragmentary isometric showing a portion of
`the panel of FIG. 70 from above the panel.
`FIG. 78 is a view similar to FIG. 77 showing a portion of
`the panel from beneath the panel.
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`is in a retracted position.
`FIG. 86 is a view similar to FIG. 74 showing an alterna-
`tive arrangement of the compressive triangle embodiment
`wherein the rigid strips are flat and planar in configuration.
`FIG. 87 is a view similar to FIG. 86 wherein the rigid
`strips are arcuate in transverse cross-section and down-
`wardly convex.
`FIG. 88 is a view similar to FIG. 87 wherein thestrips are
`arcuate in cross-section and downwardly concave.
`FIG. 89 is a view similar to FIG. 86 wherein the rigid
`strips are substantially S-shaped configuration and down-
`wardly concave.
`FIG. 90 is a view similar to FIG. 89 wherein the rigid
`strips are generally S-shaped configuration and downwardly
`convex.
`
`FIG. 91 is a view similar to FIG. 89 whereinthe flat planar
`rigid strips have been positioned at a different angular
`orientation relative to each other than as shownin FIG. 86.
`
`FIG. 92 is a view similar to FIG. 86 wherein the rigid flat
`planarstrips are positioned at a still different angular posi-
`tion.
`
`FIG. 93 is a fragmentary isometric looking down on a
`compressive triangle embodiment of the panel wherein the
`rigid strips are laminated.
`FIG. 94 is a fragmentary isometric similar to FIG. 93
`looking at the panel from the underside.
`FIG. 95 is a fragmentary isometric showing a tension
`triangle embodiment of the present invention.
`FIG. 96 is a longitudinal section taken through the panel
`of FIG. 95 illustrating the two sheet-like layers of material
`and the struts in each cell separating the layers.
`FIG. 97 is a fragmentary section showing the intercon-
`nection of the sheets of material shown in FIG. 96.
`
`FIG. 98 is a fragmentary isometric showing a different
`arrangement of the tens