US20070094965A1 - Method and Apparatus For Spanning Gutter Gaps in Wall Panels - Google Patents
Method and Apparatus For Spanning Gutter Gaps in Wall Panels Download PDFInfo
- Publication number
- US20070094965A1 US20070094965A1 US11/610,584 US61058406A US2007094965A1 US 20070094965 A1 US20070094965 A1 US 20070094965A1 US 61058406 A US61058406 A US 61058406A US 2007094965 A1 US2007094965 A1 US 2007094965A1
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- United States
- Prior art keywords
- perimeter framing
- framing members
- wall
- adjacent
- flexible sheet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0801—Separate fastening elements
- E04F13/0803—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
- E04F13/081—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements
- E04F13/0821—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements located in-between two adjacent covering elements
- E04F13/0826—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements located in-between two adjacent covering elements engaging side grooves running along the whole length of the covering elements
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0889—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F19/00—Other details of constructional parts for finishing work on buildings
- E04F19/02—Borders; Finishing strips, e.g. beadings; Light coves
- E04F19/06—Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T137/00—Fluid handling
- Y10T137/0318—Processes
- Y10T137/0402—Cleaning, repairing, or assembling
- Y10T137/0441—Repairing, securing, replacing, or servicing pipe joint, valve, or tank
- Y10T137/048—With content loading or unloading [e.g., dispensing, discharge assistant, etc.]
Definitions
- the present invention is directed generally to apparatus and methods for erecting wall panels and specifically to perimeter framing members for attaching wall panels to structural members.
- the exterior walls of many commercial and industrial buildings are formed by mounting a number of wall panels and attached perimeter extrusions on a grid framework of structural members attached to the building.
- the resulting grid of wall panels are aesthetically attractive and protect the building structure from fluids in the terrestrial environment.
- the joints between the wall panels should be substantially sealed from terrestrial fluids. Penetration of terrestrial fluids behind the wall panels can cause warpage and/or dislocation of the wall panels, which can culminate in wall panel failure.
- any sealing material used in the joints between the wall panels should be non-skinning and non-hardening. The sealing material is located in a confined space in the joint. To maintain the integrity of the seal between the wall panels when the panels expand and contract in response to thermal fluctuations and other building movements (e.g., seismically induced movements), the sealing material must be able to move with the wall panels without failure of the seal.
- the sealing material hardens or “sets up”, the sealing material can break or shear, thereby destroying the weather seal.
- the longevity of the sealing material should be at least as long as the useful life of the wall panels.
- the sealing material should be capable of being pre-installed before erection of a wall panel beside a previously installed wall panel to provide for ease and simplicity of wall panel installation and low installation costs.
- Wall panel systems presently must be installed in a “stair step” fashion (i.e., a staggered or stepped method) because the sealing material must be installed only after both of the adjacent wall panels are mounted on the support members.
- a drainage system or gutter should be employed to drain any fluids that are able to penetrate the seal in the joints.
- the gutter which commonly is a “U”-shaped member in communication with a series of weep holes, must not overflow and thereby provide an uncontrolled entry for terrestrial fluids into the interior of the wall.
- winds can exert a positive pressure on the wall, thereby forcing terrestrial fluids to adhere to the surface of the wall (i.e., known as a capillary attraction).
- the fluids can be drawn through the weep holes into gutter.
- the amount of terrestrial fluids drawn through the weep holes is directly proportional to the intensity of the storm pressure exerted on the wall exterior. If a sufficient amount of fluids enter the weep holes, the gutter can overflow, leaking fluids into the wall interior. Such leakage can cause severe damage or even panel failure.
- the wall panel attachment system includes an upper perimeter framing member attached to an upper wall panel and a lower perimeter framing member attached to a lower wall panel.
- the upper and lower perimeter framing members engage one another at perimeter edges of the upper and lower, typically vertically aligned, wall panels to define a recess relative to the upper and lower wall panels.
- At least one of the upper and lower perimeter framing members includes a plurality of drainage (or weep) holes for the drainage of terrestrial fluids located inside of the upper and lower perimeter framing members.
- At least one of the upper and lower perimeter framing members further includes a capillary break or blocking means (e.g., an elongated ridge running the length of the perimeter framing members) that (a) projects into the recess, (b) is positioned between the exterior of the upper and lower wall panels on the one hand and the plurality of drainage holes on the other, (c) is positioned on the same side of the recess as the plurality of drainage holes, and (d) is spaced from the plurality of drainage holes.
- the portion of the recess located interiorly of the capillary break is referred to as the circulating chamber.
- the capillary break inhibits terrestrial fluids, such as rainwater, from entering the plurality of drainage holes and substantially seals the joint between the upper and lower perimeter framing members from penetration by fluids.
- the capillary break induces vortexing of any air stream containing droplets, thereby removing the droplets from the air stream upstream of the weep holes.
- Vortexing is induced by a decrease in the cross-sectional area of airflow (causing an increase in air stream velocity) as the air stream flows towards and past the capillary break followed by a sudden increase in the cross-sectional area of flow downstream of the capillary break (causing a decrease in air stream velocity).
- the sudden decrease in air stream velocity causes entrained droplets to deposit on the surface of the recess.
- the capillary break can have a concave or curved surface on its rear surface (adjacent to the circulating chamber). The rear surface of the capillary break is adjacent to the weep holes.
- the weep holes must be located at a sufficient distance from the capillary break and a sufficient distance above the free end of the capillary break to remove the weep holes from the vortex.
- the capillary break and weep holes are both positioned on the same side of a horizontal line intersecting the free end of the capillary break.
- the distance between the rear surface of the capillary break and the adjacent drainage holes is at least about 0.25 inches.
- the distance of the weep holes above the free end of the capillary break is at least about 125% of the distance from the free end of the capillary break to the opposing surface of the recess.
- the drainage holes and capillary break can be located on the same perimeter framing member or on different perimeter framing members.
- a second aspect of the present invention employs a flexible sheet interlock, that is substantially impervious to the passage of terrestrial fluids, to overlap both of the perimeter framing members to inhibit the passage of terrestrial fluids in the space between the perimeter framing members.
- the flexible sheet interlock is preferably composed of a sealing non-skinning and non-hardening material that has a useful life at least equal to that of the wall panels. In this manner, the integrity of the seal between the wall panels is maintained over the useful life of the panels.
- the most preferred sealing material is silicone or urethane.
- the flexible sheet interlock can be pre-installed before erection of an adjacent wall panel to provide for ease and simplicity of wall panel installation and low installation costs.
- the flexible sheet interlock can be installed on the wall panel and folded back on itself during installation of the adjacent wall panel. After the adjacent wall panel is installed, the interlock can simply be unfolded to cover the joint between the adjoining wall panels.
- FIG. 1 depicts a number of adjoining wall panels attached by a first embodiment of the wall panel mounting system according to a first aspect of the present invention
- FIG. 1A is an exploded view of interconnected upper and lower perimeter framing members attached to panels 54 a and 54 c of the first embodiment viewed from in front of the wall panels, with a portion of the lower perimeter framing member 58 c being cutaway to reveal the drainage holes 78 (in the lower perimeter framing member 58 c , as is also illustrated in FIG. 2 ), and the capillary break 74 (in the upper perimeter framing member 66 a , as is also illustrated in FIG. 2 );
- FIG. 1B is an exploded view of the lower perimeter framing member 58 b of the first embodiment
- FIG. 1C is an exploded view of interconnected upper and lower perimeter framing members 66 b and 58 d of the first embodiment
- FIG. 1D is an exploded view of the upper perimeter framing member 58 d of the first embodiment
- FIG. 2 is a cross-sectional view of the wall panel mounting system of the first embodiment taken along lines 2 - 2 of FIG. 1 ;
- FIG. 3 is a sectional view of the wall panel mounting system of the first embodiment taken along lines 2 - 2 of FIG. 1 depicting the impact of the capillary break on airflow during a storm;
- FIG. 4 is a second embodiment of a wall panel mounting system according to the first aspect of the present invention.
- FIG. 5 is a third embodiment of a wall panel mounting system according to the first aspect of the present invention.
- FIG. 6A depicts a number of adjoining wall panels sealed by a fourth embodiment of a wall panel mounting system according to the second aspect of the present invention briefly described in the Summary of the Invention section hereinabove;
- FIG. 6B is an exploded view of interconnected lower perimeter framing members, e.g., 66 a and 66 b , of adjoining wall panels 54 c and 54 d of FIG. 6A viewed from the front of the wall panels, with the upper perimeter framing member removed to reveal the flexible sheet interlock 250 ;
- lower perimeter framing members e.g., 66 a and 66 b
- FIG. 7 depicts the behavior of the flexible sheet interlock 250 in response to thermal contractions in the wall panels
- FIG. 8 depicts a first method for installing the flexible sheet interlock to seal a joint between adjacent perimeter framing members
- FIG. 9 is a sectional view along line 9 - 9 of FIG. 8 ;
- FIGS. 10-11 depict a second method for installing the flexible sheet interlock which uses a rigid insert to protect the edges of the flexible sheet interlock;
- FIGS. 12-13 depict a third method for installing the flexible sheet interlock which uses a shelf or lip on the perimeter framing member to protect the edges of the flexible sheet interlock;
- FIG. 14 depicts the exposed edges of the flexible sheet interlock being folded back onto itself during installation of an adjacent wall panel
- FIG. 15 depicts a preferred sequence for installing wall panels using the flexible sheet interlock, wherein instances of the flexible sheet interlock are identified by the label “FSI”;
- FIGS. 16-22 depict a fourth embodiment of a wall panel mounting system according to a third aspect of the present invention.
- FIGS. 23-28 depict a fifth embodiment of a wall panel mounting system according to the third aspect of the present invention.
- FIG. 1 depicts four adjacent wall panel mounting assemblies 50 a - d and the attached vertically oriented wall panels 54 a - d according to the first aspect of the present invention.
- Each wall panel mounting assembly 50 a - d includes a number of perimeter framing members 58 a - d , 62 a - d , 66 a - d and 70 a - d engaging each edge of the wall panels 54 a - d .
- Lower perimeter framing members 58 engage upper perimeter framing members 66
- perimeter framing members 62 engage perimeter framing members 70 .
- FIGS. 1 depicts four adjacent wall panel mounting assemblies 50 a - d and the attached vertically oriented wall panels 54 a - d according to the first aspect of the present invention.
- Each wall panel mounting assembly 50 a - d includes a number of perimeter framing members 58 a - d , 62 a - d , 66 a -
- the upper perimeter framing members 66 are configured to interlock in a nested relationship with corresponding lower perimeter framing members 58 (e.g., 58 c and 58 d ).
- the upper and lower perimeter framing members has a capillary break 74 ( FIGS. 1C and 2 as well), and a plurality of drainage holes 78 a - c in communication with a gutter 83 ( FIG. 2 as well), defined by the lower perimeter framing member in the present embodiment.
- the wall panels 54 can be composed of a variety of materials, including wood, plastics, metal, ceramics, masonry, and composites thereof.
- a preferred composite wall panel 54 is metal- or plastic-faced with a wood, metal, or plastic core.
- a more preferred wall panel 54 is a composite of metal and plastics sold under the trademark “ALUCOBOND ”.
- the upper and lower perimeter framing members 66 and 58 define a recess 82 .
- the capillary break 74 extends downwardly from the upper perimeter framing member 66 to divide the recess 82 into a circulating chamber 86 and an inlet 90 .
- the capillary break 74 is located nearer the wall panel 54 than the drainage holes 78 to block or impede the flow of droplets 94 ( FIG. 3 ) entrained in the air stream 98 into the drainage holes 78 .
- FIG. 3 depicts the operation of the capillary break 74 and circulating chamber 86 during a storm.
- the air stream or wind 98 forces droplets of water 94 against the wall panels 54 (e.g., 54 b and 54 d ).
- a film 102 of water forms on, e.g., the exterior surfaces of the wall.
- the wind pressure forces entrained droplets of water 94 and the film 102 into the inlet 90 between the wall panels 54 b and 54 d .
- the capillary break 74 which runs continuously along the length of each upper perimeter framing member 66 (e.g., 66 b in FIG. 3 ), decreases the cross-sectional area of air flow and therefore increases the velocity of the droplets 94 .
- the cross-sectional area of flow increases and therefore the velocity of the droplets 94 decreases forming a vortex 106 .
- the droplets 94 have insufficient velocity to remain entrained in the air and the droplets collect in the film 102 on the lower surface 110 of the recess 82 .
- the degree of vortexing of the air stream depends, of course, on the increase in the cross-sectional area of flow as the air stream flows past the capillary break 74 and into the circulating chamber 86 . If one were to define the space between the free end 124 ( FIG. 2 ) of the capillary break and the opposing wall (i.e., lower surface 110 ) of the recess 82 as having a first vertical cross-sectional area, and the space between the vertically spaced apart opposing walls of the circulating chamber 86 (i.e., the distance “H v ”, FIG. 2 ) as having a second vertical cross-sectional area, the second vertical cross sectional area is preferably at least about 125% of the first vertical cross sectional area and more preferably at least about 150% of the first vertical cross sectional area.
- the rear surface 120 ( FIGS. 2 and 3 ) of the capillary break 74 has a concave or curved shape to facilitate the formation of the vortex 106 .
- the relative dimensions of the capillary break 74 are important to its performance.
- the height “H C ” ( FIG. 2 ) of the capillary break 74 is at least about 100%, and more preferably ranges from about 125% to about 200%, of the distance “D C ” ( FIG. 2 ) between the free end 124 of the capillary break 74 and the opposing surface 110 of the recess 82 .
- the locations of the drainage holes 78 relative to the capillary break 74 is another important factor to performance.
- the drainage holes 78 are preferably located on the same side of the capillary break 74 as the circulating chamber 86 of the recess 82 (i.e., drainage holes 78 are in the upper portion of the circulating chamber 86 as shown in FIG. 2 ) such that the wind does not have a straight line path from the inlet 90 to a drainage hole 78 .
- the distance “D H ” ( FIG. 2 ) from the rear surface 120 of the capillary break 74 to the edge 128 ( FIG. 2 ) of the drainage hole 78 must be sufficient to place the drainage hole outside of the vortex and more preferably is at least about 0.25 inches.
- FIG. 4 depicts a second embodiment of a wall panel mounting assembly according to the first aspect of the present invention (this first aspect briefly described in the Summary of the Invention section hereinabove).
- drainage holes 78 are located on a substantially vertical surface 154 of an embodiment of the lower perimeter framing member 58 . Because a vertically oriented drainage hole is more susceptible to the entry of fluids than the horizontally oriented drainage hole of FIG. 2 , the preferred minimum distance “D H ” from the rear surface 120 of the capillary break 74 for this second embodiment is greater than the preferred minimum distance “D H ” from the rear surface for the first embodiment (e.g., FIG. 2 ).
- the drainage hole 78 is located at least about 0.75 inches from the rear surface 120 of the capillary break 74 .
- the center of the drainage hole 78 is located above the free end 124 ( FIG. 4 ) of the capillary break 74 and more preferably the entire drainage hole 78 is located above the free end 124 of the capillary break 74 .
- FIG. 5 depicts a third embodiment of a wall panel mounting assembly according to the first aspect of the present invention.
- drainage holes 78 are located above the free end 124 of the capillary break 74 with an inclined surface 212 extending from the drainage holes 78 to a point below the capillary break 74 .
- the inclined surface 212 facilitates removal of fluids from the recess 82 and thereby inhibits build-up of fluids in a corner of the recess 82 (i.e., a corner of the chamber 86 ).
- FIGS. 6A and 6B depict a fourth embodiment of a wall panel attachment system according to the second aspect of the present invention (this second aspect briefly described in the Summary of the Invention section hereinabove).
- the system uses a flexible sheet interlock 250 ( FIG. 6B ) to seal inline adjacent perimeter framing members (e.g., perimeter framing members 258 a and 258 b , which may correspond to one of the pairs of lower perimeter framing members 58 a,b or 58 c,d of FIGS. 1, 1A and 1 C).
- perimeter framing members e.g., perimeter framing members 258 a and 258 b , which may correspond to one of the pairs of lower perimeter framing members 58 a,b or 58 c,d of FIGS. 1, 1A and 1 C).
- a flexible sheet interlock 250 inhibits fluid migration along the joint defined by the adjacent ends 254 a,b of the adjacent gutter segments (e.g., 83 a,b in FIG. 6B ) of the perimeter framing members 258 a and 258 b .
- the flexible sheet interlock 250 realizes this result by retaining fluids in the adjacent gutter segments 83 a,b. Accordingly, the interface (e.g., 260 , FIG. 7 ) between the flexible sheet interlock 250 and the gutter interior surfaces of the gutter walls 268 a,b,c is substantially impervious to fluid migration.
- the flexible sheet interlock 250 has sufficient flexibility to conform to the “U”-shaped contour of the gutter segments 83 a and 83 b.
- surface 251 of the flexible sheet interlock 250 between the adjacent ends 254 a,b is shown, and in particular, in FIG. 7 , this surface is shown in both an extended and bowed configuration.
- the interface 260 ( FIG. 7 ) can include an adhesive 264 between the flexible sheet interlock 250 and each of the three gutter walls 268 a,b,c to retain the interlock 250 in position.
- an adhesive preferably having sealing properties, has been found to assist the formation and maintenance of an integral seal between the interlock 250 and the gutter interior surfaces of the gutter walls 268 a,b,c .
- the most preferred adhesive is a high performance compressed joint sealant that can “set up” or harden and bond to the gutter walls 268 a,b,c and the interlock.
- sealants include silicone, urethane, and epoxy. Because the interlock 250 itself absorbs all of the thermal movement of the wall panels, there is no requirement for the adhesive 264 to stay resilient and move. The end result is a more economical system for sealing the gap 284 between the gutter segments 83 a,b of adjacent perimeter framing members (e.g., 258 a, b ) that has a useful life equal to that of the exterior wall panel system.
- the portion 280 of the interlock 250 in the gap 284 between the adjoining perimeter framing members deforms and thereby absorbs the movement without a failure of the seal provided by the adhesive 264 .
- the perimeter framing members e.g., 258 a, b
- the interlock 250 returns to its normal (i.e., extended) position.
- FIGS. 8 and 9 embodiments of lower perimeter framing members 58 e and 58 f are shown, and additionally these figures show that the dimensions of the flexible interlock 250 are sufficient to prevent fluids from spilling over the sides of the interlock 250 before the fluid depth in the gutter 83 (provided by gutter segments 83 a,b ) reaches the depth of the gutter.
- the two heights labeled “H F 1 ” and “H F 2 ” ( FIG. 9 ) of the respective sides 272 a,c of the interlock 250 are substantially the same as the heights “H I 1 ” and “H I 2 ” of the corresponding (i.e., adjacent) side walls 268 a,c of the gutter.
- FIGS. 8-9 also depict a method for installing the interlock 250 across the adjacent ends of the gutter segments 83 a,b .
- the interlock 250 is pressed down in the gutter segments 83 a,b until the interlock 250 substantially conforms to the interior shape of the gutter 83 as depicted in FIG. 9 .
- FIGS. 10-13 alternative methods are depicted for installing the flexible sheet interlock 250 in the gutters 83 (e.g., gutter segments 83 a,b in FIG. 6B ).
- a substantially rigid insert 292 can be employed to protect the exposed edge 293 of the interlock 250 during engagement of an upper perimeter framing member, and a lower perimeter framing member.
- the rigid insert 292 is shown in the context of another embodiment of the upper and lower perimeter framing members identified respectively in these figures by the labels 266 and 258 . Note that the upper perimeter framing member 266 adjoins an upper wall panel 54 k , and the lower perimeter framing member 258 adjoins a lower wall panel 54 m .
- the inner surface 296 of the upper perimeter framing member 266 can “roll up” the interlock 250 due to frictional forces during engagement of the upper and lower perimeter framing members 266 and 258 with one another.
- the “L”-shaped insert 292 which can be any substantially rigid material such as metal or plastic, is received between the upper and lower perimeter framing members ( 266 , 258 , respectively), and inhibits the rolling up of the interlock 250 when the perimeter framing members are placed into an interlocking relationship.
- the insert 292 and interlock 250 are positioned in a nested interlocking relationship as shown in FIG. 10 . To operate effectively, the height “H A ” of the engaging surface 297 ( FIG.
- the insert 292 has substantially the same length as the height “H I ” ( FIG. 10 ) of the corresponding (i.e., adjacent) gutter wall 268 a .
- the insert 292 is not required to be an “L”-shape but can be any other shape that matches the inner contour of the gutter 83 such as a “U”-shape.
- FIGS. 10-11 also show other features for the wall panel attachment system disclosed herein.
- a pocket 289 is shown in each of: the lower perimeter framing member 266 , and (in the dashed version of) the upper perimeter framing member 258 .
- Each pocket 289 is a recess into which a corresponding portion of a panel 54 (e.g., 54 k or 54 m ) can be received (e.g., a portion of the panel that is: (a) between the panel peripheral surfaces 55 and 57 , and (b) extending to the panel's peripheral edge 56 , wherein the panel surfaces 55 and 57 face substantially away from one another).
- Each pocket 289 is bounded by (and in part defined by) a pair of first and second opposing surfaces, 286 and 287 respectively.
- an attachment member 290 is also provided in each pocket 289 .
- one of the attachment members 290 is operably provided in the perimeter framing member's corresponding pocket 289 for securing a corresponding one of the panels 54 m and 54 k within the pocket (for example, wherein the peripheral surfaces 55 and 57 , and, the edge 56 of the panel are received within the pocket 289 ). More precisely, for each of the attachment members 290 :
- the inner surface 299 of the gutter segment 83 a includes a lip 302 extending inwardly to protect the edges of the interlock 250 during installation of the upper perimeter framing member 266 .
- the width of the lip “H L ” ( FIG. 12 ) is preferably at least the same as the thickness “T I ” ( FIG. 13 ) of the interlock 250 .
- FIGS. 14 and 15 depict a preferred method for installing wall panel systems using the flexible sheet interlock 250 (identified by the label “FSI” in FIG. 15 ).
- the numbers on the wall panels e.g., 1st, 2nd, 3rd, etc. in FIG. 15 ) denote the order in which the wall panels are attached to the wall support members.
- the conventional “stair step” method can also be employed with the interlock 250 , the method of FIG. 15 is simpler, less expensive, and has more flexibility in installation.
- the wall panel system 500 a ( FIG. 15 ) is attached to the wall support members.
- the adhesive 264 ( FIG. 7 ) is applied to either or both of a flexible sheet interlock 250 and adjoining interior gutter surfaces of walls 268 a - c ( FIG. 14 ), and the flexible sheet interlock 250 is engaged with each end 254 a,b ( FIGS. 6B and 14 ) of the wall panel system 500 a .
- the wall panel systems 500 b,c are attached to the wall support members, wherein the corresponding flexible sheet interlocks 250 are attached to the ends of each system's gutter segment (e.g., 83 a or 83 b ) as described above.
- the protruding end 504 of the interlock 250 is folded away from the edge of the wall panel system 500 a as shown in FIG. 14 , and the wall panel system 500 d is attached to the wall support members.
- a flexible sheet interlock 250 is then attached to the gutter segment (e.g., 83 a or 83 b ) at the end of the wall panel system 500 d as described hereinabove.
- the above steps are repeated to install the remaining wall panel systems 500 e - 500 l.
- the third aspect of the invention is used to attach embodiments of the wall panels to an alternative embodiment of the perimeter framing members denoted by the label 304 to distinguish it from the perimeter framing members described hereinabove.
- the wall panel assembly 300 (e.g., FIG. 19 ) includes a perimeter framing member 304 , a wedge-shaped member 306 , and an attachment member 308 (which secures a wall panel within a pocket 289 , but differently from attachment member 290 , FIG. 10 , and which is preferably a rigid or semi-rigid material such as metal).
- the attachment member 308 has an L-shaped member 312 that engages a grooved member 316 in the perimeter framing member 304 .
- the attachment member 308 has a cylindrically-shaped bearing surface 320 that is received in a groove 324 in a wall panel 54 (also identified as a panel member 54 herein) substantially along the length of the side of the panel member 54 .
- One end 336 of the wedge-shaped member 306 engages a step 332 in the perimeter framing member 304 and the other end 340 of the wedge-shaped member 306 engages a step 344 in the attachment member 308 .
- the wedge-shaped member 306 is suitably sized to cause the bearing surface 320 of the attachment member 308 to be forced against the groove 324 in the panel member, thereby holding the panel member in position.
- the bearing surface 320 can have any number of desired shapes, including v-shaped, star-shaped, and the like.
- FIGS. 16-21 The steps to assemble the panel member assembly 300 are illustrated in FIGS. 16-21 .
- the panel member 54 is positioned in the pocket 289 of the perimeter framing member 304 .
- the L-shaped member 312 (which is part of the attachment member 308 ) is engaged with the grooved member 316 ( FIG. 18 ) of the perimeter framing member 304 , and the bearing surface 320 is engaged with the groove in the panel member 54 .
- FIGS. 18-19 the lower end 340 of the wedge-shaped member 306 is engaged with the step 344 of the attachment member, and the upper end 336 of the wedge-shaped member 306 is then forcibly engaged with the step 332 in the perimeter framing member 304 . Note that as shown in FIG. 18 , for an axis 351 :
- the attachment member 308 includes a portion that traverses the extent or separation between the first position and the second position. In the present embodiment, one such portion is the part of the attachment member 308 that extends from the bearing surface 320 to the dashed line 355 .
- the edge of the panel member 54 is bent at a 90 degree angle about a predetermined line in the panel member. Interlocking flanges of adjacent perimeter framing members can then be engaged to form the building surface.
- FIGS. 22-28 depict a fifth embodiment according to the third aspect of the present invention.
- the wedge-shaped member 306 of the previous embodiment of FIGS. 16-21 is replaced with a screw 404 ( FIGS. 23-28 , alternatively, screw 404 a or 404 b in FIG. 22 ) or other fastener to hold the perimeter framing member 304 ( FIGS. 23-28 , alternatively, perimeter framing member 304 a or 304 b in FIG. 22 ), and the attachment member 308 ( FIGS. 23-28 , alternatively, attachment member 308 a or 308 b in FIG. 22 ) in position on the panel member 54 ( FIGS. 23-28 , alternatively, panel 54 n or 54 p in FIG. 22 ).
- the fastener passes through the attachment member and perimeter framing member.
- FIGS. 23-28 The steps to assemble each panel member assembly 300 of FIG. 22 are illustrated by FIGS. 23-28 , with FIG. 23 illustrating the first step, FIG. 24 the second step, FIGS. 25-26 the third step, and FIGS. 27-28 the last step. Additionally, note that FIG. 22 depicts a somewhat different embodiment from that of FIGS. 23-28 ; e.g., FIG. 22 shows differently configured perimeter framing members 304 a,b and attachment members 308 a,b from the corresponding components in FIGS. 23-28 .
- the perimeter framing members 304 a,b ( FIG. 22 ) are in the interlocked position for mounting the panels on a support surface.
- FIG. 22 shows the parallel surfaces 412 a and 412 b of the peripheral edges of the panels 54 n and 54 p , wherein each of the surfaces 412 a and 412 b engage an interior surface of a corresponding pocket 289 of one of the perimeter framing members 304 a and 304 b (such perimeter framing members also referred to as panel receiving members herein).
- the panels 54 n and 54 p are spaced apart from one another by a channel or gap 424 , wherein the channel or gap is bounded by facing sides, each side being provided by a different one of first and second perimeter framing members 304 a and 304 b , and each side being an exterior surface of one of the pockets 289 receiving a corresponding peripheral edge of one of the panels 54 n and 54 p.
Abstract
The wall panel system of the present invention includes a flexible sheet interlock to flexibly seal a joint defined by adjacent perimeter framing members and a capillary break to inhibit the entry of water into drainage or weep holes in gutters in the perimeter framing member.
Description
- The present application is a continuation of U.S. patent application Ser. No. 09/886,297, filed Jun. 20, 2001, entitled “METHOD AND APPARATUS FOR ERECTING WALL PANELS”, which is a continuation application of 09/334,124, filed Jun. 15, 1999, entitled “METHOD AND APPARATUS FOR ERECTING WALL PANELS” now U.S. Pat. No. 6,330,772, which is a continuation application of U.S. patent application Ser. No. 08/989,748, filed Dec. 12, 1997, now U.S. Pat. No. 5,916,100, all the above identified references being fully incorporated herein by this reference.
- The present invention is directed generally to apparatus and methods for erecting wall panels and specifically to perimeter framing members for attaching wall panels to structural members.
- The exterior walls of many commercial and industrial buildings are formed by mounting a number of wall panels and attached perimeter extrusions on a grid framework of structural members attached to the building. The resulting grid of wall panels are aesthetically attractive and protect the building structure from fluids in the terrestrial environment.
- In designing a wall panel mounting system, there are a number of objectives. First, the joints between the wall panels should be substantially sealed from terrestrial fluids. Penetration of terrestrial fluids behind the wall panels can cause warpage and/or dislocation of the wall panels, which can culminate in wall panel failure. Second, any sealing material used in the joints between the wall panels should be non-skinning and non-hardening. The sealing material is located in a confined space in the joint. To maintain the integrity of the seal between the wall panels when the panels expand and contract in response to thermal fluctuations and other building movements (e.g., seismically induced movements), the sealing material must be able to move with the wall panels without failure of the seal. If the sealing material hardens or “sets up”, the sealing material can break or shear, thereby destroying the weather seal. Third, the longevity of the sealing material should be at least as long as the useful life of the wall panels. Fourth, the sealing material should be capable of being pre-installed before erection of a wall panel beside a previously installed wall panel to provide for ease and simplicity of wall panel installation and low installation costs. Wall panel systems presently must be installed in a “stair step” fashion (i.e., a staggered or stepped method) because the sealing material must be installed only after both of the adjacent wall panels are mounted on the support members. Fifth, a drainage system or gutter should be employed to drain any fluids that are able to penetrate the seal in the joints. The gutter, which commonly is a “U”-shaped member in communication with a series of weep holes, must not overflow and thereby provide an uncontrolled entry for terrestrial fluids into the interior of the wall. During storms, winds can exert a positive pressure on the wall, thereby forcing terrestrial fluids to adhere to the surface of the wall (i.e., known as a capillary attraction). In other words, as the fluids follow the wall profile, the fluids can be drawn through the weep holes into gutter. The amount of terrestrial fluids drawn through the weep holes is directly proportional to the intensity of the storm pressure exerted on the wall exterior. If a sufficient amount of fluids enter the weep holes, the gutter can overflow, leaking fluids into the wall interior. Such leakage can cause severe damage or even panel failure.
- These and other design considerations are addressed by the wall panel attachment system of the present invention. In a first aspect of the present invention, the wall panel attachment system includes an upper perimeter framing member attached to an upper wall panel and a lower perimeter framing member attached to a lower wall panel. The upper and lower perimeter framing members engage one another at perimeter edges of the upper and lower, typically vertically aligned, wall panels to define a recess relative to the upper and lower wall panels. At least one of the upper and lower perimeter framing members includes a plurality of drainage (or weep) holes for the drainage of terrestrial fluids located inside of the upper and lower perimeter framing members. At least one of the upper and lower perimeter framing members further includes a capillary break or blocking means (e.g., an elongated ridge running the length of the perimeter framing members) that (a) projects into the recess, (b) is positioned between the exterior of the upper and lower wall panels on the one hand and the plurality of drainage holes on the other, (c) is positioned on the same side of the recess as the plurality of drainage holes, and (d) is spaced from the plurality of drainage holes. The portion of the recess located interiorly of the capillary break is referred to as the circulating chamber. The capillary break inhibits terrestrial fluids, such as rainwater, from entering the plurality of drainage holes and substantially seals the joint between the upper and lower perimeter framing members from penetration by fluids.
- While not wishing to be bound by any theory, the capillary break induces vortexing of any air stream containing droplets, thereby removing the droplets from the air stream upstream of the weep holes. Vortexing is induced by a decrease in the cross-sectional area of airflow (causing an increase in air stream velocity) as the air stream flows towards and past the capillary break followed by a sudden increase in the cross-sectional area of flow downstream of the capillary break (causing a decrease in air stream velocity). Behind and adjacent to the capillary break, the sudden decrease in air stream velocity causes entrained droplets to deposit on the surface of the recess. To induce vortexing, the capillary break can have a concave or curved surface on its rear surface (adjacent to the circulating chamber). The rear surface of the capillary break is adjacent to the weep holes.
- To inhibit entry of the droplets into the weep holes adjacent to the capillary break, the weep holes must be located at a sufficient distance from the capillary break and a sufficient distance above the free end of the capillary break to remove the weep holes from the vortex. Preferably, the capillary break and weep holes are both positioned on the same side of a horizontal line intersecting the free end of the capillary break. Typically, the distance between the rear surface of the capillary break and the adjacent drainage holes (which are typically aligned relative to a common axis) is at least about 0.25 inches. Commonly, the distance of the weep holes above the free end of the capillary break is at least about 125% of the distance from the free end of the capillary break to the opposing surface of the recess.
- The drainage holes and capillary break can be located on the same perimeter framing member or on different perimeter framing members.
- To form a seal between the perimeter framing members of adjacent, horizontally aligned wall panels, a second aspect of the present invention employs a flexible sheet interlock, that is substantially impervious to the passage of terrestrial fluids, to overlap both of the perimeter framing members to inhibit the passage of terrestrial fluids in the space between the perimeter framing members.
- The flexible sheet interlock is preferably composed of a sealing non-skinning and non-hardening material that has a useful life at least equal to that of the wall panels. In this manner, the integrity of the seal between the wall panels is maintained over the useful life of the panels. The most preferred sealing material is silicone or urethane. The flexible sheet interlock, being non-skinning and non-hardening, can move freely, in response to thermally induced movement of the wall panels, without failure of the seal.
- The flexible sheet interlock can be pre-installed before erection of an adjacent wall panel to provide for ease and simplicity of wall panel installation and low installation costs. The flexible sheet interlock can be installed on the wall panel and folded back on itself during installation of the adjacent wall panel. After the adjacent wall panel is installed, the interlock can simply be unfolded to cover the joint between the adjoining wall panels.
-
FIG. 1 depicts a number of adjoining wall panels attached by a first embodiment of the wall panel mounting system according to a first aspect of the present invention; -
FIG. 1A is an exploded view of interconnected upper and lower perimeter framing members attached topanels perimeter framing member 58 c being cutaway to reveal the drainage holes 78 (in the lowerperimeter framing member 58 c, as is also illustrated inFIG. 2 ), and the capillary break 74 (in the upperperimeter framing member 66 a, as is also illustrated inFIG. 2 ); -
FIG. 1B is an exploded view of the lowerperimeter framing member 58 b of the first embodiment; -
FIG. 1C is an exploded view of interconnected upper and lowerperimeter framing members -
FIG. 1D is an exploded view of the upperperimeter framing member 58 d of the first embodiment; -
FIG. 2 is a cross-sectional view of the wall panel mounting system of the first embodiment taken along lines 2-2 ofFIG. 1 ; -
FIG. 3 is a sectional view of the wall panel mounting system of the first embodiment taken along lines 2-2 ofFIG. 1 depicting the impact of the capillary break on airflow during a storm; -
FIG. 4 is a second embodiment of a wall panel mounting system according to the first aspect of the present invention; -
FIG. 5 is a third embodiment of a wall panel mounting system according to the first aspect of the present invention; -
FIG. 6A depicts a number of adjoining wall panels sealed by a fourth embodiment of a wall panel mounting system according to the second aspect of the present invention briefly described in the Summary of the Invention section hereinabove; -
FIG. 6B is an exploded view of interconnected lower perimeter framing members, e.g., 66 a and 66 b, of adjoiningwall panels FIG. 6A viewed from the front of the wall panels, with the upper perimeter framing member removed to reveal theflexible sheet interlock 250; -
FIG. 7 depicts the behavior of theflexible sheet interlock 250 in response to thermal contractions in the wall panels; -
FIG. 8 depicts a first method for installing the flexible sheet interlock to seal a joint between adjacent perimeter framing members; -
FIG. 9 is a sectional view along line 9-9 ofFIG. 8 ; -
FIGS. 10-11 depict a second method for installing the flexible sheet interlock which uses a rigid insert to protect the edges of the flexible sheet interlock; -
FIGS. 12-13 depict a third method for installing the flexible sheet interlock which uses a shelf or lip on the perimeter framing member to protect the edges of the flexible sheet interlock; -
FIG. 14 depicts the exposed edges of the flexible sheet interlock being folded back onto itself during installation of an adjacent wall panel; -
FIG. 15 depicts a preferred sequence for installing wall panels using the flexible sheet interlock, wherein instances of the flexible sheet interlock are identified by the label “FSI”; -
FIGS. 16-22 depict a fourth embodiment of a wall panel mounting system according to a third aspect of the present invention; and -
FIGS. 23-28 depict a fifth embodiment of a wall panel mounting system according to the third aspect of the present invention. - The first aspect of the present invention is directed to retarding the passage of terrestrial fluids through the joint between adjoining upper and lower wall panels.
FIG. 1 depicts four adjacent wallpanel mounting assemblies 50 a-d and the attached vertically orientedwall panels 54 a-d according to the first aspect of the present invention. Each wallpanel mounting assembly 50 a-d includes a number ofperimeter framing members 58 a-d, 62 a-d, 66 a-d and 70 a-d engaging each edge of thewall panels 54 a-d. Lowerperimeter framing members 58 engage upperperimeter framing members 66, and perimeter framing members 62 engage perimeter framing members 70. As can be seen fromFIGS. 1A and 1C , the upper perimeter framing members 66 (e.g., 66 a and 66 b) are configured to interlock in a nested relationship with corresponding lower perimeter framing members 58 (e.g., 58 c and 58 d). Referring toFIG. 1A , at least one of the upper and lower perimeter framing members has a capillary break 74 (FIGS. 1C and 2 as well), and a plurality ofdrainage holes 78 a-c in communication with a gutter 83 (FIG. 2 as well), defined by the lower perimeter framing member in the present embodiment. - The
wall panels 54 can be composed of a variety of materials, including wood, plastics, metal, ceramics, masonry, and composites thereof. A preferredcomposite wall panel 54 is metal- or plastic-faced with a wood, metal, or plastic core. A morepreferred wall panel 54 is a composite of metal and plastics sold under the trademark “ALUCOBOND ”. - Referring to
FIGS. 1C, 2 and 3, the upper and lowerperimeter framing members recess 82. Thecapillary break 74 extends downwardly from the upperperimeter framing member 66 to divide therecess 82 into a circulatingchamber 86 and aninlet 90. Thecapillary break 74 is located nearer thewall panel 54 than the drainage holes 78 to block or impede the flow of droplets 94 (FIG. 3 ) entrained in theair stream 98 into the drainage holes 78. -
FIG. 3 depicts the operation of thecapillary break 74 and circulatingchamber 86 during a storm. The air stream orwind 98 forces droplets ofwater 94 against the wall panels 54 (e.g., 54 b and 54 d). Afilm 102 of water forms on, e.g., the exterior surfaces of the wall. The wind pressure forces entrained droplets ofwater 94 and thefilm 102 into theinlet 90 between thewall panels capillary break 74, which runs continuously along the length of each upper perimeter framing member 66 (e.g., 66 b inFIG. 3 ), decreases the cross-sectional area of air flow and therefore increases the velocity of thedroplets 94. As the entraineddroplets 94 enter the circulatingchamber 86, the cross-sectional area of flow increases and therefore the velocity of thedroplets 94 decreases forming avortex 106. As a result, thedroplets 94 have insufficient velocity to remain entrained in the air and the droplets collect in thefilm 102 on thelower surface 110 of therecess 82. - The degree of vortexing of the air stream depends, of course, on the increase in the cross-sectional area of flow as the air stream flows past the
capillary break 74 and into the circulatingchamber 86. If one were to define the space between the free end 124 (FIG. 2 ) of the capillary break and the opposing wall (i.e., lower surface 110) of therecess 82 as having a first vertical cross-sectional area, and the space between the vertically spaced apart opposing walls of the circulating chamber 86 (i.e., the distance “Hv”,FIG. 2 ) as having a second vertical cross-sectional area, the second vertical cross sectional area is preferably at least about 125% of the first vertical cross sectional area and more preferably at least about 150% of the first vertical cross sectional area. - The rear surface 120 (
FIGS. 2 and 3 ) of thecapillary break 74 has a concave or curved shape to facilitate the formation of thevortex 106. - The relative dimensions of the
capillary break 74 are important to its performance. Preferably, the height “HC” (FIG. 2 ) of thecapillary break 74 is at least about 100%, and more preferably ranges from about 125% to about 200%, of the distance “DC” (FIG. 2 ) between thefree end 124 of thecapillary break 74 and the opposingsurface 110 of therecess 82. - The locations of the drainage holes 78 relative to the
capillary break 74 is another important factor to performance. The drainage holes 78 are preferably located on the same side of thecapillary break 74 as the circulatingchamber 86 of the recess 82 (i.e., drainage holes 78 are in the upper portion of the circulatingchamber 86 as shown inFIG. 2 ) such that the wind does not have a straight line path from theinlet 90 to adrainage hole 78. For a substantially horizontally orienteddrainage hole 78, the distance “DH” (FIG. 2 ) from therear surface 120 of thecapillary break 74 to the edge 128 (FIG. 2 ) of thedrainage hole 78 must be sufficient to place the drainage hole outside of the vortex and more preferably is at least about 0.25 inches. -
FIG. 4 depicts a second embodiment of a wall panel mounting assembly according to the first aspect of the present invention (this first aspect briefly described in the Summary of the Invention section hereinabove). In this second embodiment, drainage holes 78 are located on a substantiallyvertical surface 154 of an embodiment of the lowerperimeter framing member 58. Because a vertically oriented drainage hole is more susceptible to the entry of fluids than the horizontally oriented drainage hole ofFIG. 2 , the preferred minimum distance “DH” from therear surface 120 of thecapillary break 74 for this second embodiment is greater than the preferred minimum distance “DH” from the rear surface for the first embodiment (e.g.,FIG. 2 ). More preferably, thedrainage hole 78 is located at least about 0.75 inches from therear surface 120 of thecapillary break 74. The center of thedrainage hole 78 is located above the free end 124 (FIG. 4 ) of thecapillary break 74 and more preferably theentire drainage hole 78 is located above thefree end 124 of thecapillary break 74. -
FIG. 5 depicts a third embodiment of a wall panel mounting assembly according to the first aspect of the present invention. In this third embodiment, drainage holes 78 are located above thefree end 124 of thecapillary break 74 with aninclined surface 212 extending from the drainage holes 78 to a point below thecapillary break 74. Theinclined surface 212 facilitates removal of fluids from therecess 82 and thereby inhibits build-up of fluids in a corner of the recess 82 (i.e., a corner of the chamber 86). -
FIGS. 6A and 6B depict a fourth embodiment of a wall panel attachment system according to the second aspect of the present invention (this second aspect briefly described in the Summary of the Invention section hereinabove). The system uses a flexible sheet interlock 250 (FIG. 6B ) to seal inline adjacent perimeter framing members (e.g.,perimeter framing members perimeter framing members 58 a,b or 58 c,d ofFIGS. 1, 1A and 1C). At the joint orgap 284 between theperimeter framing members adjacent wall panels 54 a,b (or 54 c,d), aflexible sheet interlock 250 inhibits fluid migration along the joint defined by the adjacent ends 254 a,b of the adjacent gutter segments (e.g., 83 a,b inFIG. 6B ) of theperimeter framing members flexible sheet interlock 250 realizes this result by retaining fluids in theadjacent gutter segments 83 a,b. Accordingly, the interface (e.g., 260,FIG. 7 ) between theflexible sheet interlock 250 and the gutter interior surfaces of thegutter walls 268 a,b,c is substantially impervious to fluid migration. As can be seen fromFIG. 6B , theflexible sheet interlock 250 has sufficient flexibility to conform to the “U”-shaped contour of thegutter segments - Referring to
FIGS. 6A, 6B , andFIG. 7 ,surface 251 of theflexible sheet interlock 250 between the adjacent ends 254 a,b is shown, and in particular, inFIG. 7 , this surface is shown in both an extended and bowed configuration. The interface 260 (FIG. 7 ) can include an adhesive 264 between theflexible sheet interlock 250 and each of the threegutter walls 268 a,b,c to retain theinterlock 250 in position. Although theflexible sheet interlock 250 itself may possess adhesive properties, an adhesive, preferably having sealing properties, has been found to assist the formation and maintenance of an integral seal between theinterlock 250 and the gutter interior surfaces of thegutter walls 268 a,b,c. The most preferred adhesive is a high performance compressed joint sealant that can “set up” or harden and bond to thegutter walls 268 a,b,c and the interlock. Examples of such sealants include silicone, urethane, and epoxy. Because theinterlock 250 itself absorbs all of the thermal movement of the wall panels, there is no requirement for the adhesive 264 to stay resilient and move. The end result is a more economical system for sealing thegap 284 between thegutter segments 83 a,b of adjacent perimeter framing members (e.g., 258 a, b) that has a useful life equal to that of the exterior wall panel system. - As can be seen from
FIG. 7 , when the perimeter framing members (e.g., 258 a, b) are expanded due to thermal or building movements (e.g., the perimeter framing member positions denoted by arrows 274), theportion 280 of theinterlock 250 in thegap 284 between the adjoining perimeter framing members deforms and thereby absorbs the movement without a failure of the seal provided by the adhesive 264. When the perimeter framing members (e.g., 258 a, b) are in a relaxed state (e.g., the perimeter framing member positions denoted by arrows 288), theinterlock 250 returns to its normal (i.e., extended) position. - Referring to
FIGS. 8 and 9 , embodiments of lowerperimeter framing members flexible interlock 250 are sufficient to prevent fluids from spilling over the sides of theinterlock 250 before the fluid depth in the gutter 83 (provided bygutter segments 83 a,b) reaches the depth of the gutter. After installation of theinterlock 250 in thegutter 83, the two heights labeled “HF1 ” and “HF2 ” (FIG. 9 ) of therespective sides 272 a,c of theinterlock 250 are substantially the same as the heights “HI1 ” and “HI2 ” of the corresponding (i.e., adjacent)side walls 268 a,c of the gutter. -
FIGS. 8-9 also depict a method for installing theinterlock 250 across the adjacent ends of thegutter segments 83 a,b. Theinterlock 250 is pressed down in thegutter segments 83 a,b until theinterlock 250 substantially conforms to the interior shape of thegutter 83 as depicted inFIG. 9 . - In
FIGS. 10-13 , alternative methods are depicted for installing theflexible sheet interlock 250 in the gutters 83 (e.g.,gutter segments 83 a,b inFIG. 6B ). In a second method shown inFIGS. 10-11 , a substantiallyrigid insert 292 can be employed to protect the exposededge 293 of theinterlock 250 during engagement of an upper perimeter framing member, and a lower perimeter framing member. In particular, therigid insert 292 is shown in the context of another embodiment of the upper and lower perimeter framing members identified respectively in these figures by thelabels perimeter framing member 266 adjoins anupper wall panel 54 k, and the lowerperimeter framing member 258 adjoins alower wall panel 54 m. As will be appreciated, in the absence of theinsert 292, theinner surface 296 of the upperperimeter framing member 266 can “roll up” theinterlock 250 due to frictional forces during engagement of the upper and lowerperimeter framing members insert 292, which can be any substantially rigid material such as metal or plastic, is received between the upper and lower perimeter framing members (266, 258, respectively), and inhibits the rolling up of theinterlock 250 when the perimeter framing members are placed into an interlocking relationship. Theinsert 292 and interlock 250 are positioned in a nested interlocking relationship as shown inFIG. 10 . To operate effectively, the height “HA” of the engaging surface 297 (FIG. 11 ) of theinsert 292 has substantially the same length as the height “HI” (FIG. 10 ) of the corresponding (i.e., adjacent)gutter wall 268 a. As will be appreciated, theinsert 292 is not required to be an “L”-shape but can be any other shape that matches the inner contour of thegutter 83 such as a “U”-shape. - Note that
FIGS. 10-11 also show other features for the wall panel attachment system disclosed herein. In particular, apocket 289 is shown in each of: the lowerperimeter framing member 266, and (in the dashed version of) the upperperimeter framing member 258. Eachpocket 289 is a recess into which a corresponding portion of a panel 54 (e.g., 54 k or 54 m) can be received (e.g., a portion of the panel that is: (a) between the panelperipheral surfaces peripheral edge 56, wherein the panel surfaces 55 and 57 face substantially away from one another). Eachpocket 289 is bounded by (and in part defined by) a pair of first and second opposing surfaces, 286 and 287 respectively. In addition to a panel's peripheral surfaces and edges, anattachment member 290 is also provided in eachpocket 289. For each of the lower and upperperimeter framing members attachment members 290 is operably provided in the perimeter framing member'scorresponding pocket 289 for securing a corresponding one of thepanels peripheral surfaces edge 56 of the panel are received within the pocket 289). More precisely, for each of the attachment members 290: - (i) there is a corresponding semi-cylindrical grove or notch 285 within a surface of the corresponding
adjacent panel 54 for mating with (or more generally, engaging) acorresponding surface portion 290 a (also referred to as a “bearing surface”) of theattachment member 290, and - (ii) there is a corresponding semi-cylindrical groove (or more generally, “grooved member”) 291 in each of the first of the opposing
surfaces 286 for mating with (or generally, engaging) acorresponding surface portion 290 b (also referred to as a “bearing surface”) of theattachment member 290. - In a third method for installing the
flexible sheet interlock 250 shown inFIGS. 12-13 , theinner surface 299 of thegutter segment 83 a includes alip 302 extending inwardly to protect the edges of theinterlock 250 during installation of the upperperimeter framing member 266. The width of the lip “HL” (FIG. 12 ) is preferably at least the same as the thickness “TI” (FIG. 13 ) of theinterlock 250. -
FIGS. 14 and 15 depict a preferred method for installing wall panel systems using the flexible sheet interlock 250 (identified by the label “FSI” inFIG. 15 ). The numbers on the wall panels (e.g., 1st, 2nd, 3rd, etc. inFIG. 15 ) denote the order in which the wall panels are attached to the wall support members. Although the conventional “stair step” method can also be employed with theinterlock 250, the method ofFIG. 15 is simpler, less expensive, and has more flexibility in installation. - The installation method will now be explained with reference to
FIGS. 8-9 and 14-15. In a first step, thewall panel system 500 a (FIG. 15 ) is attached to the wall support members. In a second step, the adhesive 264 (FIG. 7 ) is applied to either or both of aflexible sheet interlock 250 and adjoining interior gutter surfaces of walls 268 a-c (FIG. 14 ), and theflexible sheet interlock 250 is engaged with eachend 254 a,b (FIGS. 6B and 14 ) of thewall panel system 500 a. In a third step, thewall panel systems 500 b,c are attached to the wall support members, wherein the correspondingflexible sheet interlocks 250 are attached to the ends of each system's gutter segment (e.g., 83 a or 83 b) as described above. In a fourth step, theprotruding end 504 of theinterlock 250 is folded away from the edge of thewall panel system 500 a as shown inFIG. 14 , and thewall panel system 500 d is attached to the wall support members. Aflexible sheet interlock 250 is then attached to the gutter segment (e.g., 83 a or 83 b) at the end of thewall panel system 500 d as described hereinabove. The above steps are repeated to install the remaining wall panel systems 500 e-500 l. - Referring to
FIGS. 16-21 , a fourth embodiment according to a third aspect of the present invention is illustrated. The third aspect of the invention is used to attach embodiments of the wall panels to an alternative embodiment of the perimeter framing members denoted by thelabel 304 to distinguish it from the perimeter framing members described hereinabove. The wall panel assembly 300 (e.g.,FIG. 19 ) includes aperimeter framing member 304, a wedge-shapedmember 306, and an attachment member 308 (which secures a wall panel within apocket 289, but differently fromattachment member 290,FIG. 10 , and which is preferably a rigid or semi-rigid material such as metal). Theattachment member 308 has an L-shapedmember 312 that engages agrooved member 316 in theperimeter framing member 304. Theattachment member 308 has a cylindrically-shapedbearing surface 320 that is received in agroove 324 in a wall panel 54 (also identified as apanel member 54 herein) substantially along the length of the side of thepanel member 54. Oneend 336 of the wedge-shapedmember 306 engages astep 332 in theperimeter framing member 304 and theother end 340 of the wedge-shapedmember 306 engages astep 344 in theattachment member 308. The wedge-shapedmember 306 is suitably sized to cause thebearing surface 320 of theattachment member 308 to be forced against thegroove 324 in the panel member, thereby holding the panel member in position. The bearingsurface 320 can have any number of desired shapes, including v-shaped, star-shaped, and the like. - The steps to assemble the
panel member assembly 300 are illustrated inFIGS. 16-21 . In the first step illustrated byFIG. 16 , thepanel member 54 is positioned in thepocket 289 of theperimeter framing member 304. InFIG. 17 , the L-shaped member 312 (which is part of the attachment member 308) is engaged with the grooved member 316 (FIG. 18 ) of theperimeter framing member 304, and thebearing surface 320 is engaged with the groove in thepanel member 54. InFIGS. 18-19 , thelower end 340 of the wedge-shapedmember 306 is engaged with thestep 344 of the attachment member, and theupper end 336 of the wedge-shapedmember 306 is then forcibly engaged with thestep 332 in theperimeter framing member 304. Note that as shown inFIG. 18 , for an axis 351: - (i) having a
first position 352 a that is offset from thesurface 353 of thepanel member 54 on a side also having thesurface 354 of thepocket 289, and - (ii) having a second position 352 b that is offset from the
surface 353 on a side not having thesurface 354, - the
attachment member 308 includes a portion that traverses the extent or separation between the first position and the second position. In the present embodiment, one such portion is the part of theattachment member 308 that extends from the bearingsurface 320 to the dashedline 355. InFIGS. 20-21 , the edge of thepanel member 54 is bent at a 90 degree angle about a predetermined line in the panel member. Interlocking flanges of adjacent perimeter framing members can then be engaged to form the building surface. -
FIGS. 22-28 depict a fifth embodiment according to the third aspect of the present invention. The wedge-shapedmember 306 of the previous embodiment ofFIGS. 16-21 ) is replaced with a screw 404 (FIGS. 23-28 , alternatively, screw 404 a or 404 b inFIG. 22 ) or other fastener to hold the perimeter framing member 304 (FIGS. 23-28 , alternatively,perimeter framing member FIG. 22 ), and the attachment member 308 (FIGS. 23-28 , alternatively,attachment member FIG. 22 ) in position on the panel member 54 (FIGS. 23-28 , alternatively,panel FIG. 22 ). The fastener passes through the attachment member and perimeter framing member. - The steps to assemble each
panel member assembly 300 ofFIG. 22 are illustrated byFIGS. 23-28 , withFIG. 23 illustrating the first step,FIG. 24 the second step,FIGS. 25-26 the third step, andFIGS. 27-28 the last step. Additionally, note thatFIG. 22 depicts a somewhat different embodiment from that ofFIGS. 23-28 ; e.g.,FIG. 22 shows differently configuredperimeter framing members 304 a,b andattachment members 308 a,b from the corresponding components inFIGS. 23-28 . - The
perimeter framing members 304 a,b (FIG. 22 ) are in the interlocked position for mounting the panels on a support surface. Note thatFIG. 22 shows theparallel surfaces panels surfaces corresponding pocket 289 of one of theperimeter framing members panels gap 424, wherein the channel or gap is bounded by facing sides, each side being provided by a different one of first and secondperimeter framing members pockets 289 receiving a corresponding peripheral edge of one of thepanels - While various embodiments have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the scope of these inventions, as set forth in the following claims.
Claims (19)
1. A wall system including a plurality of wall panels attached to a structural member, comprising:
adjacent perimeter framing members, each framing member having a horizontal extent that: (a) extends horizontally to opposite ends of the framing member, and (b) extents horizontally beyond the horizontal extent of the other perimeter framing member;
wherein each of the perimeter framing members is attached horizontally to a different wall panel, the wall panels being located in a side-by-side relationship; and
a flexible sheet interlock, that is substantially impervious to fluids, wherein the flexible sheet interlock extends a channel for fluids across a gap between ends of first and second fluid channel segments, each fluid channel segment operably connected to one of the adjacent perimeter framing members for providing a corresponding predetermined fluid path, wherein the channel channels fluids across the gap and along the horizontal extents of each of the adjacent perimeter framing members.
2. The apparatus of claim 1 , further comprising: an upper perimeter framing member attached to an upper wall panel, and at least one of the adjacent perimeter framing members attached to a lower wall panel, the upper perimeter framing member and the at least one of the adjacent perimeter framing members engaging one another at perimeter edges of the upper and lower wall panels to define a recess relative to the upper and lower wall panels, the recess having an opening between a lower edge of the upper wall panel and an upper edge of the lower wall panel;
wherein at least one of the upper perimeter framing member and the at least one of the adjacent perimeter framing members includes a plurality of drainage holes for the drainage of fluids located inside of the upper and lower wall panels, and at least one of the upper perimeter framing members and the at least one of the adjacent perimeter framing members includes a capillary break: (i) projecting into the recess and positioned between the upper and lower wall panels, (ii) positioned on the same side of the recess as the plurality of drainage holes, (iii) spaced from the plurality of drainage holes to inhibit fluids from entering the plurality of drainage holes, and (iv) dividing the opening from a circulating chamber of the recess, the drainage holes draining into the circulating chamber;
wherein the recess has a lower surface contoured for permitting fluids in the circulating chamber to discharge into an exterior environment via the opening.
3. The wall system of claim 2 , wherein a first space between a free end of the capillary break and an opposing wall of the recess has a first vertical cross-sectional area, and a second space between opposing walls of the recess at a point between the capillary break and the plurality of drainage holes has a second vertical cross-sectional area and the second vertical cross sectional area is at least about 125% of the first vertical cross sectional area for creating, in combination with a curved surface of the capillary break, a vortex between the opposing walls of the recess at a point between the capillary break and the plurality of drainage holes.
4. The wall system of claim 2 , wherein a distance between the capillary break and a drainage hole is at least about 0.25 inches.
5. The wall system of claim 2 , wherein the centers of the plurality of drainage holes lie along a common axis.
6. The wall system of claim 2 , wherein a surface of the capillary break adjacent to the plurality of drainage holes is concave.
7. The wall system of claim 2 , wherein the plurality of drainage holes are spaced at regular intervals along the at least one of the upper and lower perimeter framing members.
8. The wall system of claim 2 , wherein the plurality of drainage holes are located on the at least one of the adjacent perimeter framing member and the capillary break is located on the upper perimeter framing member.
9. The wall system of claim 2 , wherein the plurality of drainage holes are located on a substantially horizontal surface.
10. The wall system of claim 2 , wherein the plurality of drainage holes are located on one of the upper perimeter framing member and the at least one of the adjacent perimeter framing members, and the capillary break is located on the other of one of the upper perimeter framing member and the at least one of the adjacent perimeter framing members.
11. The wall system of claim 1 , wherein the flexible sheet interlock is composed of silicone.
12. The wall system of claim 1 , wherein the flexible sheet interlock is attached to each of the adjacent perimeter framing members by a sealant having a different composition than the flexible sheet interlock.
13. The wall system of claim 1 , further comprising a substantially rigid insert and an upper perimeter framing member that is in an interlocking relationship with at least one of the adjacent perimeter framing members, the substantially rigid insert being located between the upper perimeter framing member and the flexible sheet interlock to retain the flexible sheet interlock in position.
14. The wall system of claim 1 , further comprising an upper perimeter framing member that is in an interlocking relationship with at least one of the adjacent perimeter framing members, the at least one of the adjacent perimeter framing members including a lip projecting inwardly and being located adjacent to an end of the flexible sheet interlock to retain the flexible sheet interlock in position.
15. The wall system of claim 1 , wherein the adjacent perimeter framing members are positioned in an end-to-end relationship with one another.
16. A wall including a plurality of wall panels attached to a structural member, comprising:
adjacent perimeter framing members, each framing member having a horizontal extent that: (a) extends horizontally to opposite ends of the framing member, and (b) extents horizontally beyond the horizontal extent of the other perimeter framing member, each of the perimeter framing members being attached horizontally to a different wall panel, the wall panels being located in a side-by-side relationship; and
a flexible sheet interlock, that is substantially impervious to fluids, wherein the flexible sheet interlock extends a channel for fluids across a gap between ends of first and second fluid channel segments, each fluid channel segment operably connected to one of the adjacent perimeter framing members for providing a corresponding predetermined fluid path, wherein the channel channels fluids across the gap and along the horizontal extents of each of the adjacent perimeter framing members, wherein at least one of the adjacent perimeter framing members includes retaining means for retaining an end of the flexible sheet interlock in position when a third perimeter framing member is placed in an interlocking relationship with the at least one of the adjacent perimeter framing members.
17. The wall system of claim 1 , further including a retaining means for retaining the flexible sheet interlock in a position for conducting the fluids between the first and second fluid channel segments, the retaining means including at least one of a substantially rigid insert and a lip projecting from the at least one of the adjacent perimeter framing members.
18. A method for erecting a wall from a plurality of wall panels, each respective wall panel being attached to a corresponding plurality of perimeter framing members, comprising:
engaging a first wall panel attached to a first plurality of perimeter framing members to a structural member;
engaging a second wall panel attached to a second plurality of perimeter framing members to a structural member, the second wall panel being located above the first wall panel;
wherein for at least one perimeter framing member (S) of the second plurality of perimeter framing members, and at least one perimeter framing member (F) of the of the first plurality of perimeter framing members, the perimeter framing member S engages a bottom edge of the second wall panel, and the perimeter framing member F engages a top edge of the first wall panel;
attaching a flexible sheet interlock to the perimeter framing member F;
engaging a third wall panel attached to a third plurality of perimeter framing members to a structural member, the third wall panel being located beside the first wall panel and below the second wall panel, and at least one perimeter framing members (T) of the of the third plurality of perimeter framing members engaging the perimeter framing member F;
wherein each of the perimeter framing members F and T have a horizontal extent that: (a) extends horizontally to opposite ends of the perimeter framing member, and (b) extents horizontally beyond the horizontal extent of the other of the perimeter framing members F and T; and
attaching the flexible sheet interlock to the perimeter framing member T for providing a channel for fluids across a space between ends of first and second fluid channel segments, each fluid channel segment operably connected to one of the perimeter framing members F and T for providing a corresponding predetermined fluid path, wherein the channel channels fluids across the gap and along the horizontal extents of each of the perimeter framing members F and T.
19. A wall system for engaging a structural member, comprising:
a plurality of wall panels; and
adjacent perimeter framing members located in a side-by-side relationship, each of the adjacent perimeter framing members attached to a different wall panel, the wall panels being located in a side-by-side relationship; and
a flexible sheet interlock, that is substantially impervious to terrestrial fluids, overlaps each of the adjacent perimeter framing members to inhibit the passage of terrestrial fluids between the adjacent perimeter framing members.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US11/610,584 US20070094965A1 (en) | 1997-12-12 | 2006-12-14 | Method and Apparatus For Spanning Gutter Gaps in Wall Panels |
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Application Number | Priority Date | Filing Date | Title |
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US08/989,748 US5916100A (en) | 1997-12-12 | 1997-12-12 | Method and apparatus for erecting wall panels |
US09/334,124 US6330772B1 (en) | 1997-12-12 | 1999-06-15 | Method and apparatus for erecting wall panels |
US09/886,297 US7272913B2 (en) | 1997-12-12 | 2001-06-20 | Method and apparatus for erecting wall panels |
US11/610,584 US20070094965A1 (en) | 1997-12-12 | 2006-12-14 | Method and Apparatus For Spanning Gutter Gaps in Wall Panels |
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US09/886,297 Continuation US7272913B2 (en) | 1997-12-12 | 2001-06-20 | Method and apparatus for erecting wall panels |
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US20070094965A1 true US20070094965A1 (en) | 2007-05-03 |
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US09/334,124 Expired - Lifetime US6330772B1 (en) | 1997-12-12 | 1999-06-15 | Method and apparatus for erecting wall panels |
US09/886,297 Expired - Fee Related US7272913B2 (en) | 1997-12-12 | 2001-06-20 | Method and apparatus for erecting wall panels |
US10/138,444 Expired - Fee Related US7614191B2 (en) | 1997-12-12 | 2002-05-02 | Method and apparatus for erecting wall panels |
US10/437,549 Expired - Fee Related US7516583B2 (en) | 1997-12-12 | 2003-05-13 | Method and apparatus for erecting wall panels |
US11/610,584 Abandoned US20070094965A1 (en) | 1997-12-12 | 2006-12-14 | Method and Apparatus For Spanning Gutter Gaps in Wall Panels |
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US09/886,297 Expired - Fee Related US7272913B2 (en) | 1997-12-12 | 2001-06-20 | Method and apparatus for erecting wall panels |
US10/138,444 Expired - Fee Related US7614191B2 (en) | 1997-12-12 | 2002-05-02 | Method and apparatus for erecting wall panels |
US10/437,549 Expired - Fee Related US7516583B2 (en) | 1997-12-12 | 2003-05-13 | Method and apparatus for erecting wall panels |
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- 1997-12-12 US US08/989,748 patent/US5916100A/en not_active Expired - Lifetime
-
1998
- 1998-12-14 CA CA 2255535 patent/CA2255535C/en not_active Expired - Fee Related
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1999
- 1999-06-15 US US09/334,124 patent/US6330772B1/en not_active Expired - Lifetime
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2001
- 2001-06-20 US US09/886,297 patent/US7272913B2/en not_active Expired - Fee Related
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2002
- 2002-05-02 US US10/138,444 patent/US7614191B2/en not_active Expired - Fee Related
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2003
- 2003-05-13 US US10/437,549 patent/US7516583B2/en not_active Expired - Fee Related
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2006
- 2006-12-14 US US11/610,584 patent/US20070094965A1/en not_active Abandoned
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US20020134034A1 (en) * | 1997-12-12 | 2002-09-26 | Elward Systems Corporation | Method and apparatus for erecting wall panels |
US20030192270A1 (en) * | 1997-12-12 | 2003-10-16 | Elward Systems Corporation | Method and apparatus for erecting wall panels |
US7516583B2 (en) | 1997-12-12 | 2009-04-14 | Elward Systems Corporation | Method and apparatus for erecting wall panels |
US7614191B2 (en) | 1997-12-12 | 2009-11-10 | Elward Systems Corporation | Method and apparatus for erecting wall panels |
US20080134594A1 (en) * | 2006-12-11 | 2008-06-12 | The Carvist Corporation | Exterior building panel |
US7562509B2 (en) * | 2006-12-11 | 2009-07-21 | The Carvist Corporation | Exterior building panel with condensation draining system |
US20090056262A1 (en) * | 2007-08-31 | 2009-03-05 | Kelly Thomas L | System and method for waterproofing parapet walls |
US7594369B2 (en) * | 2007-08-31 | 2009-09-29 | Kelly Thomas L | System and method for waterproofing parapet walls |
US20130326972A1 (en) * | 2011-02-16 | 2013-12-12 | Johann Aschauer | Structural design with rear-ventilated cladding elements |
US8850761B2 (en) * | 2011-02-16 | 2014-10-07 | Johann Aschauer | Structural design with rear-ventilated cladding elements |
Also Published As
Publication number | Publication date |
---|---|
US7516583B2 (en) | 2009-04-14 |
US5916100A (en) | 1999-06-29 |
CA2255535C (en) | 2009-03-24 |
US20020026758A1 (en) | 2002-03-07 |
CA2255535A1 (en) | 1999-06-12 |
US6330772B1 (en) | 2001-12-18 |
US20030192270A1 (en) | 2003-10-16 |
US7272913B2 (en) | 2007-09-25 |
US20020134034A1 (en) | 2002-09-26 |
US7614191B2 (en) | 2009-11-10 |
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Legal Events
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AS | Assignment |
Owner name: ELWARD SYSTEMS CORPORATION, COLORADO Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:MITCHELL, JED D.;REEL/FRAME:018761/0670 Effective date: 20061214 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |