U.S. patent application number 11/610584 was filed with the patent office on 2007-05-03 for method and apparatus for spanning gutter gaps in wall panels.
This patent application is currently assigned to ELWARD SYSTEMS CORPORATION. Invention is credited to Jed D. Mitchell.
Application Number | 20070094965 11/610584 |
Document ID | / |
Family ID | 25535427 |
Filed Date | 2007-05-03 |
United States Patent
Application |
20070094965 |
Kind Code |
A1 |
Mitchell; Jed D. |
May 3, 2007 |
Method and Apparatus For Spanning Gutter Gaps in Wall Panels
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.
Inventors: |
Mitchell; Jed D.; (Lakewood,
CO) |
Correspondence
Address: |
SHERIDAN ROSS PC
1560 BROADWAY
SUITE 1200
DENVER
CO
80202
US
|
Assignee: |
ELWARD SYSTEMS CORPORATION
680 Harlan Street
Lakewood
CO
80214
|
Family ID: |
25535427 |
Appl. No.: |
11/610584 |
Filed: |
December 14, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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09886297 |
Jun 20, 2001 |
|
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11610584 |
Dec 14, 2006 |
|
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09334124 |
Jun 15, 1999 |
6330772 |
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09886297 |
Jun 20, 2001 |
|
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08989748 |
Dec 12, 1997 |
5916100 |
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09334124 |
Jun 15, 1999 |
|
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Current U.S.
Class: |
52/302.1 |
Current CPC
Class: |
E04F 13/0826 20130101;
Y10T 137/048 20150401; E04F 19/06 20130101; E04F 13/0889
20130101 |
Class at
Publication: |
052/302.1 |
International
Class: |
E04B 1/70 20060101
E04B001/70 |
Claims
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.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] 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.
FIELD OF THE INVENTION
[0002] 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.
BACKGROUND OF THE INVENTION
[0003] 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.
[0004] 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.
SUMMARY OF THE INVENTION
[0005] 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.
[0006] 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.
[0007] 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.
[0008] The drainage holes and capillary break can be located on the
same perimeter framing member or on different perimeter framing
members.
[0009] 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.
[0010] 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.
[0011] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] 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;
[0013] FIG. 1A is an exploded view of interconnected upper and
lower perimeter framing members attached to panels 54a and 54c of
the first embodiment viewed from in front of the wall panels, with
a portion of the lower perimeter framing member 58c being cutaway
to reveal the drainage holes 78 (in the lower perimeter framing
member 58c, as is also illustrated in FIG. 2), and the capillary
break 74 (in the upper perimeter framing member 66a, as is also
illustrated in FIG. 2);
[0014] FIG. 1B is an exploded view of the lower perimeter framing
member 58b of the first embodiment;
[0015] FIG. 1C is an exploded view of interconnected upper and
lower perimeter framing members 66b and 58d of the first
embodiment;
[0016] FIG. 1D is an exploded view of the upper perimeter framing
member 58d of the first embodiment;
[0017] 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;
[0018] 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;
[0019] FIG. 4 is a second embodiment of a wall panel mounting
system according to the first aspect of the present invention;
[0020] FIG. 5 is a third embodiment of a wall panel mounting system
according to the first aspect of the present invention;
[0021] 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;
[0022] FIG. 6B is an exploded view of interconnected lower
perimeter framing members, e.g., 66a and 66b, of adjoining wall
panels 54c and 54d 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;
[0023] FIG. 7 depicts the behavior of the flexible sheet interlock
250 in response to thermal contractions in the wall panels;
[0024] FIG. 8 depicts a first method for installing the flexible
sheet interlock to seal a joint between adjacent perimeter framing
members;
[0025] FIG. 9 is a sectional view along line 9-9 of FIG. 8;
[0026] 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;
[0027] 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;
[0028] FIG. 14 depicts the exposed edges of the flexible sheet
interlock being folded back onto itself during installation of an
adjacent wall panel;
[0029] 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";
[0030] FIGS. 16-22 depict a fourth embodiment of a wall panel
mounting system according to a third aspect of the present
invention; and
[0031] FIGS. 23-28 depict a fifth embodiment of a wall panel
mounting system according to the third aspect of the present
invention.
DETAILED DESCRIPTION
[0032] 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 wall panel mounting assemblies 50a-d and the attached
vertically oriented wall panels 54a-d according to the first aspect
of the present invention. Each wall panel mounting assembly 50a-d
includes a number of perimeter framing members 58a-d, 62a-d, 66a-d
and 70a-d engaging each edge of the wall panels 54a-d. Lower
perimeter framing members 58 engage upper perimeter framing members
66, and perimeter framing members 62 engage perimeter framing
members 70. As can be seen from FIGS. 1A and 1C, the upper
perimeter framing members 66 (e.g., 66a and 66b) are configured to
interlock in a nested relationship with corresponding lower
perimeter framing members 58 (e.g., 58c and 58d). Referring to FIG.
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
of drainage holes 78a-c in communication with a gutter 83 (FIG. 2
as well), defined by the lower perimeter framing member in the
present embodiment.
[0033] 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 ".
[0034] Referring to FIGS. 1C, 2 and 3, 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.
[0035] 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., 54b
and 54d). 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 54b
and 54d. The capillary break 74, which runs continuously along the
length of each upper perimeter framing member 66 (e.g., 66b in FIG.
3), decreases the cross-sectional area of air flow and therefore
increases the velocity of the droplets 94. As the entrained
droplets 94 enter the circulating chamber 86, the cross-sectional
area of flow increases and therefore the velocity of the droplets
94 decreases forming a vortex 106. As a result, 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.
[0036] 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.sub.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.
[0037] 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.
[0038] The relative dimensions of the capillary break 74 are
important to its performance. Preferably, the height "H.sub.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.sub.C" (FIG. 2) between the free end 124 of the capillary break
74 and the opposing surface 110 of the recess 82.
[0039] 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. For a substantially horizontally oriented drainage hole 78, the
distance "D.sub.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.
[0040] 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 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.sub.H" from the rear surface 120
of the capillary break 74 for this second embodiment is greater
than the preferred minimum distance "D.sub.H" from the rear surface
for the first embodiment (e.g., FIG. 2). More preferably, 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.
[0041] 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 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).
[0042] 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 258a and 258b,
which may correspond to one of the pairs of lower perimeter framing
members 58a,b or 58c,d of FIGS. 1, 1A and 1C). At the joint or gap
284 between the perimeter framing members 258a and 258b of adjacent
wall panels 54a,b (or 54c,d), a flexible sheet interlock 250
inhibits fluid migration along the joint defined by the adjacent
ends 254a,b of the adjacent gutter segments (e.g., 83a,b in FIG.
6B) of the perimeter framing members 258a and 258b. The flexible
sheet interlock 250 realizes this result by retaining fluids in the
adjacent gutter segments 83a,b. Accordingly, the interface (e.g.,
260, FIG. 7) between the flexible sheet interlock 250 and the
gutter interior surfaces of the gutter walls 268a,b,c is
substantially impervious to fluid migration. As can be seen from
FIG. 6B, the flexible sheet interlock 250 has sufficient
flexibility to conform to the "U"-shaped contour of the gutter
segments 83a and 83b.
[0043] Referring to FIGS. 6A, 6B, and FIG. 7, surface 251 of the
flexible sheet interlock 250 between the adjacent ends 254a,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 268a,b,c to retain the interlock
250 in position. Although the flexible 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 the interlock 250 and the
gutter interior surfaces of the gutter walls 268a,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 268a,b,c
and the interlock. Examples of such 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 83a,b of adjacent perimeter framing members (e.g., 258a,
b) that has a useful life equal to that of the exterior wall panel
system.
[0044] As can be seen from FIG. 7, when the perimeter framing
members (e.g., 258a, b) are expanded due to thermal or building
movements (e.g., the perimeter framing member positions denoted by
arrows 274), 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. When the perimeter framing members (e.g., 258a, b)
are in a relaxed state (e.g., the perimeter framing member
positions denoted by arrows 288), the interlock 250 returns to its
normal (i.e., extended) position.
[0045] Referring to FIGS. 8 and 9, embodiments of lower perimeter
framing members 58e and 58f 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 83a,b) reaches the depth of the gutter. After
installation of the interlock 250 in the gutter 83, the two heights
labeled "H.sub.F.sub.1" and "H.sub.F.sub.2" (FIG. 9) of the
respective sides 272a,c of the interlock 250 are substantially the
same as the heights "H.sub.I.sub.1" and "H.sub.I.sub.2" of the
corresponding (i.e., adjacent) side walls 268a,c of the gutter.
[0046] FIGS. 8-9 also depict a method for installing the interlock
250 across the adjacent ends of the gutter segments 83a,b. The
interlock 250 is pressed down in the gutter segments 83a,b until
the interlock 250 substantially conforms to the interior shape of
the gutter 83 as depicted in FIG. 9.
[0047] In FIGS. 10-13, alternative methods are depicted for
installing the flexible sheet interlock 250 in the gutters 83
(e.g., gutter segments 83a,b in FIG. 6B). In a second method shown
in FIGS. 10-11, 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. In particular, 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 54k, and the lower perimeter framing member 258
adjoins a lower wall panel 54m. As will be appreciated, in the
absence of the insert 292, 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.sub.A" of the engaging surface 297 (FIG.
11) of the insert 292 has substantially the same length as the
height "H.sub.I" (FIG. 10) of the corresponding (i.e., adjacent)
gutter wall 268a. As will be appreciated, 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.
[0048] Note that FIGS. 10-11 also show other features for the wall
panel attachment system disclosed herein. In particular, 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., 54k or 54m) 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. In addition to a panel's peripheral surfaces and
edges, an attachment member 290 is also provided in each pocket
289. For each of the lower and upper perimeter framing members 258
and 266, 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 54m and 54k 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:
[0049] (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) a corresponding surface
portion 290a (also referred to as a "bearing surface") of the
attachment member 290, and
[0050] (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) a
corresponding surface portion 290b (also referred to as a "bearing
surface") of the attachment member 290.
[0051] In a third method for installing the flexible sheet
interlock 250 shown in FIGS. 12-13, the inner surface 299 of the
gutter segment 83a 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.sub.L" (FIG.
12) is preferably at least the same as the thickness "T.sub.I"
(FIG. 13) of the interlock 250.
[0052] 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.
Although 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.
[0053] The installation method will now be explained with reference
to FIGS. 8-9 and 14-15. In a first step, the wall panel system 500a
(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 a
flexible sheet interlock 250 and adjoining interior gutter surfaces
of walls 268a-c (FIG. 14), and the flexible sheet interlock 250 is
engaged with each end 254a,b (FIGS. 6B and 14) of the wall panel
system 500a. In a third step, the wall panel systems 500b,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., 83a or 83b) as described above. In a
fourth step, the protruding end 504 of the interlock 250 is folded
away from the edge of the wall panel system 500a as shown in FIG.
14, and the wall panel system 500d is attached to the wall support
members. A flexible sheet interlock 250 is then attached to the
gutter segment (e.g., 83a or 83b) at the end of the wall panel
system 500d as described hereinabove. The above steps are repeated
to install the remaining wall panel systems 500e-500l.
[0054] 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 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.
[0055] The steps to assemble the panel member assembly 300 are
illustrated in FIGS. 16-21. In the first step illustrated by FIG.
16, the panel member 54 is positioned in the pocket 289 of the
perimeter framing member 304. In FIG. 17, 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. In 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:
[0056] (i) having a first position 352a that is offset from the
surface 353 of the panel member 54 on a side also having the
surface 354 of the pocket 289, and
[0057] (ii) having a second position 352b that is offset from the
surface 353 on a side not having the surface 354,
[0058] 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. In FIGS. 20-21, 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.
[0059] 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 404a or 404b in FIG. 22) or
other fastener to hold the perimeter framing member 304 (FIGS.
23-28, alternatively, perimeter framing member 304a or 304b in FIG.
22), and the attachment member 308 (FIGS. 23-28, alternatively,
attachment member 308a or 308b in FIG. 22) in position on the panel
member 54 (FIGS. 23-28, alternatively, panel 54n or 54p in FIG.
22). The fastener passes through the attachment member and
perimeter framing member.
[0060] 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 304a,b and attachment members 308a,b from the corresponding
components in FIGS. 23-28.
[0061] The perimeter framing members 304a,b (FIG. 22) are in the
interlocked position for mounting the panels on a support surface.
Note that FIG. 22 shows the parallel surfaces 412a and 412b of the
peripheral edges of the panels 54n and 54p, wherein each of the
surfaces 412a and 412b engage an interior surface of a
corresponding pocket 289 of one of the perimeter framing members
304a and 304b (such perimeter framing members also referred to as
panel receiving members herein). Moreover, the panels 54n and 54p
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 304a and 304b, and each side being an exterior surface of
one of the pockets 289 receiving a corresponding peripheral edge of
one of the panels 54n and 54p.
[0062] 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.
* * * * *