Decorative modular tile cladding system and method

Abstract

A decorative modular tile cladding system comprising a plurality of rectilinear or curvilinear polygonal tiles that include means for interlocking with each other to create a continuous “skin” that is used as cladding for exterior or interior surfaces of a structure. At least three separate means for interconnecting the tiles are contemplated: (1) folded tabs on each of the tiles that engage tabs on adjacent tiles to create a secure connection between tiles; (2) clips that are designed to engage the edges of adjacent tiles; (3) punched tabs or punched pockets to receive and engage a complementary tab. The tiles are attached to a standard sheathing substructure or substrate, and incorporate details for water, gas, and/or vapor exchange or expansion. In the preferred embodiment, the tiles are composed of metal, vinyl or plastic, although other materials are contemplated.

1 . A decorative modular tile cladding system for covering a surface and for conforming to any contours on said surface, said system comprising a plurality of polygonal tiles each including means for interlocking with each other so as to create a continuous and uninterrupted covering that may easily be modified to accomodate architectural elements on said surface, wherein said tiles are designed in a first and second complementary configuration such that a tile of said first configuration is interlocked with a tile of said second configuration.  
   
   
       2 . The decorative modular tile cladding system of  claim 1 , wherein said tiles include outer edges and said means for interlocking comprises two or more folded tabs disposed along said outer edges.  
   
   
       3 . The decorative modular tile cladding system of  claim 2 , wherein said tiles include top edges and bottom edges, and wherein said folded tabs include top folded tabs disposed along said top edges and bottom folded tabs disposed along said bottom edges.  
   
   
       4 . The decorative modular tile cladding system of  claim 3 , wherein said tiles include an upper surface and a lower surface, and wherein said top folded tabs are folded over said upper surface and said bottom folded tabs are folded back against said lower surface such that said upper folded tab engages said lower folded tabs on adjacent tiles.  
   
   
       5 . The decorative modular tile cladding system of  claim 4 , wherein said top folded tab includes a notch therein.  
   
   
       6 . The decorative modular tile cladding system of  claim 5 , wherein said tiles include a top leading edge and further wherein at least one hole is disposed along said top leading edge, said hole being adapted to receive a fastener, wherein said hole corresponds to said notch when said top folded tab is folded against said upper surface.  
   
   
       7 . The decorative modular tile cladding system of  claim 3 , further including weep holes provided along said bottom folded tabs to allow fluids and vapors to pass through said system.  
   
   
       8 . The decorative modular tile cladding system of  claim 2 , wherein said tabs do not meet in flush alignment, thereby allowing fluids and vapors to pass through said system.  
   
   
       9 . The decorative modular tile cladding system of  claim 1 , wherein said tiles are composed of a material that may easily be cut and shaped.  
   
   
       10 . The decorative modular tile cladding system of  claim 9 , wherein material is selected from the group consisting of metal, vinyl and plastic.  
   
   
       11 . The decorative modular tile cladding system of  claim 1 , wherein said tiles may be cut, and further including edge detailing strips for providing an aesthetically pleasing and architecturally sound cover for cut portions of said tiles.  
   
   
       12 . The decorative modular tile cladding system of  claim 1 , further including drip edges and boundary trims.  
   
   
       13 . The decorative modular tile cladding system of  claim 1 , wherein said surface includes corners, and wherein said tiles are adapted to be bent around said corners to thereby provide a continuous and uninterrupted cover.  
   
   
       14 . The decorative modular tile cladding system of  claim 1 , wherein said surface includes corners and architectural elements, and wherein said tiles are adapted to be cut to fit around said corners and said architectural elements to thereby provide a continuous and uninterrupted cover, and wherein said system further includes detailing elements to cover and dress said cut tiles.  
   
   
       15 . The decorative modular tile cladding system of  claim 1 , wherein said first configuration and said second configuration are identical.  
   
   
       16 . The decorative modular tile cladding system of  claim 1 , wherein said tiles include an extended upper surface and bottom edges having a bottom pattern, and wherein bottom folded tabs are disposed along said bottom edges and wherein at least one punched tab is provided in said extended upper surface such that said punched tabs conform to receive said bottom pattern.  
   
   
       17 . The decorative modular tile cladding system of  claim 1 , wherein said tiles include an extended upper surface and bottom edges having a bottom pattern, and wherein bottom folded tabs are disposed along said bottom edges and wherein at least one punched pocket is provided in said extended upper surface such that said punched tabs conform to said bottom pattern and further wherein the shape of said punched pocket conforms to receive said bottom folded tabs.  
   
   
       18 . The decorative modular tile cladding system of  claim 16  or  17 , wherein said first configuration and said second configuration are identical.  
   
   
       19 . A decorative modular tile cladding system for covering a surface and for conforming to any contours on said surface, said system comprising a plurality of polygonal, metal tiles each including top edges, bottom edges, an upper surface, a lower surface, and means for interlocking with each other so as to create a continuous and uninterrupted covering that may easily be modified to accomodate architectural elements on said surface, wherein said tiles are designed in a first and second complementary configuration such that a tile of said first configuration is interlocked with a tile of said second configuration, wherein said means for interlocking comprises two or more folded tabs disposed along said outer edges, and wherein said top folded tabs are folded over said upper surface and said bottom folded tabs are folded back against said lower surface such that said upper folded tab engages said lower folded tabs on adjacent tiles.  
   
   
       20 . The decorative modular tile cladding system of  claim 19 , wherein said first configuration and said second configuration are identical.  
   
   
       21 . A method for installing a decorative modular tile cladding system for covering a surface and for conforming to any contours on said surface, said method comprising the steps of: 
 providing a plurality of polygonal tiles each including means for interlocking with each other so as to create a continuous and uninterrupted covering that may easily be modified to accomodate architectural elements on said surface, wherein said tiles are designed in a first and second complementary configuration such that a tile of said first configuration is interlocked with a tile of said second configuration    attaching a tile of said first configuration to said surface using a fastener;    interlocking a tile of said second configuration to said attached tile of said first configuration;    attaching said tile of said second configuration to said surface; and    repeatedly interlocking and attaching tiles of said first configuration and said second configuration to thereby cover said surface.    
   
   
       22 . The method of  claim 21 , further including the step of first attaching a fold strip to said surface, wherein said fold strip includes means for interlocking with said tiles and wherein a first row of tiles is installed along said fold strip.  
   
   
       23 . The method of  claim 22 , wherein said tiles include an extended surface and bottom edges having a bottom pattern, and wherein bottom folded tabs are disposed along said bottom edges and wherein at least one punched tab is provided in said extended surface such that said punched tabs conform to receive said bottom pattern, further including the step of repairing said covering by removing a damaged tile and seamlessly replacing said damaged tile with a repair tile.  
   
   
       24 . The method of  claim 22 , wherein said tiles include an extended upper surface and bottom edges having a bottom pattern, and wherein bottom folded tabs are disposed along said bottom edges and wherein at least one punched pocket is provided in said extended upper surface such that said punched tabs conform to said bottom pattern and further wherein the shape of said punched pocket conforms to receive said bottom folded tabs, further including the step of repairing said covering by removing a damaged tile and seamlessly replacing said damaged tile with a repair tile.