U.S. patent application number 11/273303 was filed with the patent office on 2007-05-31 for dry joint aluminum wall panel attachment system.
Invention is credited to Philip A. MacDonald, Robert B. MacDonald.
Application Number | 20070119105 11/273303 |
Document ID | / |
Family ID | 38086073 |
Filed Date | 2007-05-31 |
United States Patent
Application |
20070119105 |
Kind Code |
A1 |
MacDonald; Robert B. ; et
al. |
May 31, 2007 |
Dry joint aluminum wall panel attachment system
Abstract
The invention provides a dry joint wall panel attachment system,
applying the rainscreen principle. Interlocking components are used
to attach aluminum wall panels to an exterior wall.
Inventors: |
MacDonald; Robert B.;
(London, CA) ; MacDonald; Philip A.; (London,
CA) |
Correspondence
Address: |
PETER L. BREWER BEARMAN, CALDWELL, & BERKOWITZ;LAW FIRM
165 MADISON AVENUE, SUITE 2000
MEMPHIS
TN
38103
US
|
Family ID: |
38086073 |
Appl. No.: |
11/273303 |
Filed: |
November 14, 2005 |
Current U.S.
Class: |
52/235 |
Current CPC
Class: |
E04F 13/0826 20130101;
E04F 13/0889 20130101; E04F 13/12 20130101 |
Class at
Publication: |
052/235 |
International
Class: |
E04H 3/00 20060101
E04H003/00; E04H 14/00 20060101 E04H014/00; E04H 5/00 20060101
E04H005/00 |
Claims
1. A dry joint aluminum wall panel attachment system for attaching
a wall panel to an exterior building wall, the system comprising: a
bracket assembly fastened to the exterior wall; an attachment clip
fastened to the bracket assembly by a fastener, the attachment clip
having a central fastening surface fastened to the bracket assembly
and at least one wing member extending outwardly from the central
fastening surface; a wall panel having an exterior flat surface and
at least two side surfaces bent generally perpendicularly to the
exterior flat surface and defining a hollow interior portion; a
panel perimeter strip fastened to one side surface of the wall
panel, the perimeter strip comprising: a generally C shaped body
member sitting inside a corner of the wall panel and extending
along an inside portion of the side surface, and a receiving member
integrally attached to the body member that extends beyond the side
surface of the wall panel and provides a slot adapted to engage and
interlock the wing member of the attachment clip, thus connecting
the wall panel to the attachment clip and thereby to the wall; an
infill strip dimensioned to fit in the slot of the panel perimeter
strip proximate to the attachment clip so as to cover the fastener;
wherein the system is held together non-adhesively and wherein the
wall panels are ventilated to permit ingress and egress of air and
moisture to provide a pressure-balanced and moisture-drained
interior environment.
2. The attachment system of claim 1, wherein the attachment clip
comprises two wing members, each adapted to engage a panel
perimeter strip of an adjacent wall panel.
3. The attachment system of claim 1, wherein the bracket assembly
comprises two back-to-back L angle brackets fastened to each other
to form a generally Z shaped assembly, a first end of which is for
attachment to the wall and a second end of which is for fastening
to the attachment clip.
4. The attachment system of claim 1, wherein the wall panels
comprise an aluminum composite material.
5. The attachment system of claim 1, wherein the wall panels
comprise an aluminum composite material which is routed and bent to
form the exterior and side surfaces.
6. The attachment system of claim 1, wherein the fastener comprises
a threaded fastener.
7. The attachment system of claim 1, wherein the panel perimeter
strip is pre-assembled to the wall panel before installation to the
wall.
8. The attachment system of claim 1, wherein the panel perimeter
strip is fastened to the wall panel by rivet.
9. The attachment system of claim 8, wherein the rivet contributes
to the ventilation of the panel system.
10. The attachment system of claim 1, wherein the infill strip is
engaged with the slot of the panel perimeter strip prior to
installing an adjacent wall panel.
11. The attachment system of claim 1, wherein the infill strip is
introduced to the slots of two adjacent panel perimeter strips
after two adjacent wall panels have been installed.
12. The attachment system of claim 1, wherein the system further
comprises an isolation tape which is applied between the attachment
clip and the bracket assembly.
13. The attachment system of claim 1, wherein the attachment clip
comprises an aluminum attachment clip.
14. The attachment system of claim 1, wherein the bracket assembly
comprises a steel bracket assembly.
15. The attachment system of claim 1, wherein the infill strip
comprises a strip of aluminum composite material.
16. The attachment system of claim 1, wherein the panel perimeter
strip is made of aluminum.
17. The attachment system of claim 1, wherein the system further
comprises a panel stiffener component placed inside the hollow
interior portion of the wall panel to reinforce the exterior
surface of the panel and prevent deforming or popping of the wall
panel.
Description
FIELD OF THE INVENTION
[0001] The invention relates to wall panel systems, and more
particularly to methods of attaching wall panels to exterior
surfaces.
BACKGROUND OF THE INVENTION
[0002] There are numerous problems with known aluminum wall panel
attachment systems. Conventionally, such systems relied upon
adhesive or caulk to "seal" the aluminum panel from the elements.
However, under heat and cold and moisture, the adhesive or caulk
breaks down compromising the stability of the system and giving an
undesirable appearance. Even when such a seal is functional, there
a tendency for undesirable effects on the aluminum panels as the
interior environment can trap heat which affects the panels,
creating "oil-canning" or popping in response to the pressure
differential. In spite of such seals, such systems can also trap
moisture in the wall cavity, which results in oxidation of parts
and staining or deterioration of exterior wall surfaces.
[0003] More recently systems have been developed according to the
"rainscreen principle" in which the wall cavity is vented,
resulting in a temperature and pressure equalized system with
adequate moisture drainage. However, such systems can be difficult
to install, relying on many components to be milled or adapted
on-site, and requiring excessive labour cost and specialty
materials. No suitable system has been developed which applies the
rainscreen principle, while providing cost-effective simple
installation.
SUMMARY OF THE INVENTION
[0004] A dry joint aluminum wall panel attachment system is
provided. The system comprises
[0005] a bracket assembly fastened to the exterior wall;
[0006] an attachment clip fastened to the bracket assembly by a
fastener, the attachment clip having a central fastening surface
fastened to the bracket assembly and at least one wing member
extending outwardly from the central fastening surface;
[0007] a wall panel having an exterior flat surface and at least
two side surfaces bent generally perpendicularly to the exterior
flat surface and defining a hollow interior portion;
[0008] a panel perimeter strip fastened to one side surface of the
wall panel, the perimeter strip comprising: [0009] a generally C
shaped body member sitting inside a corner of the wall panel and
extending along an inside portion of the side surface, and [0010] a
receiving member integrally attached to the body member that
extends beyond the side surface of the wall panel and provides a
slot adapted to engage and interlock the wing member of the
attachment clip, thus connecting the wall panel to the attachment
clip and thereby to the wall;
[0011] an infill strip dimensioned to fit in the slot of the panel
perimeter strip proximate to the attachment clip so as to cover the
fastener;
[0012] wherein the system is held together non-adhesively and
wherein the wall panels are ventilated to permit ingress and egress
of air and moisture to provide a pressure-balanced and
moisture-drained interior environment.
[0013] Preferably, the attachment clip (here aluminum) comprises
two wing members, each adapted to engage a panel perimeter strip of
an adjacent wall panel.
[0014] Preferably, the bracket assembly (here steel) comprises two
back-to-back L angle brackets fastened to each other to form a
generally Z shaped assembly, a first end of which is for attachment
to the wall and a second end of which is for fastening to the
attachment clip (such as a threaded fastener).
[0015] The wall panels comprise an aluminum composite material,
which is preferably routed and bent to form the exterior and side
surfaces. The panel perimeter strip (here aluminum) may be
pre-assembled to the wall panel before installation to the wall.
Preferably the panel perimeter strip is fastened to the wall panel
by rivet. This rivet may contribute to the ventilation of the panel
system.
[0016] The infill strip (here aluminum composite) may be engaged
with the slot of the panel perimeter strip prior to installing an
adjacent wall panel. Alternatively, the infill strip may be
introduced to the slots of two adjacent panel perimeter strips
after two adjacent wall panels have been installed.
[0017] Preferably, the system further comprises an isolation tape
which is applied between the attachment clip and the bracket
assembly.
[0018] The system may further comprise a panel stiffener component
placed inside the hollow interior portion of the wall panel to
reinforce the exterior surface of the panel and prevent deforming
or popping of the wall panel.
BRIEF DESCRIPTION OF THE FIGURES
[0019] So that the manner in which the above recited features of
the present invention can be better understood, certain drawings
are appended hereto. It is to be noted, however, that the appended
drawings illustrate only selected embodiments of the inventions and
are therefore not to be considered limiting of scope, for the
inventions may admit to other equally effective embodiments and
applications.
[0020] FIG. 1 shows a simplified cut-through view of the dry joint
aluminum wall panel attachment system, according to the preferred
embodiment.
[0021] FIG. 2 shows a panel perimeter strip used in the attachment
system.
[0022] FIG. 3 shows an attachment clip used in the attachment
system.
[0023] FIG. 4 shows a cut-through view of a panel stiffener
optionally used in the attachment system.
[0024] FIG. 5 shows a cut-through view of the aluminum composite
material (ACM) used in the panels.
[0025] FIGS. 6, 7, 8 show progressive steps in the formation of an
ACM panel for use in the present system.
[0026] FIG. 9 shows a cut-through view of an infill strip used in
the attachment system.
[0027] FIG. 10 shows a detailed view of the preferred placement of
the infill strip in the attachment system.
[0028] FIG. 11 shows a simplified elevational view of the
sub-framing used before mounting the ACM panels in the present
system.
[0029] FIG. 12 shows a detailed view of the complete attachment
system with sub-framing.
[0030] FIGS. 13, 14, 15 show progressive steps in the installation
of panels in the present system (first method).
[0031] FIG. 16 shows a view of the installation of lengths of
infill strip in the present system (second method).
[0032] FIG. 17 shows a view of a finished wall paneled
exterior.
[0033] FIG. 18 shows a cut-through view of an alternative panel
perimeter strip.
[0034] FIGS. 19-20 show cut-through views of two versions of an
alternative panel stiffener.
DETAILED DESCRIPTION
[0035] The present panel attachment system 10 uses an extruded
aluminum attachment system for fastening fabricated panels to all
building surfaces. The system's strength is further enhanced by the
use of an extruded perimeter frame design.
[0036] The system 10 is designed to the standard of the rainscreen
principle. Simply, it is designed so that the wall cavity is
vented, resulting in a pressure equalized system as seen in FIG. 1.
Controlled moisture drainage within the system, coupled with this
equalized pressure, contributes to effective, maintenance free
construction.
[0037] The extrusion process begins with an aluminum billet, the
material from which the profiles are extruded. The billet must be
softened by heat prior to extrusion process. The heated billet is
placed into the extrusion press, a powerful hydraulic device
wherein a ram pushes a dummy block that forces the softened metal
through a precision opening, known as a die, to produce the
required shapes. The extruded shape may have a mill or anodized
finish.
[0038] The system includes a panel perimeter strip 14 (FIG. 2),
which is attached to the ACM panel 32 using counter sunk rivets 36.
The panel perimeter strip is designed to fit together with the
attachment clip 16 (FIG. 3). The custom designed extrusion allows
for maximum attachment area without foregoing structural
integrity.
[0039] The attachment clip 16 (FIG. 3) is used on site to attach
the panel perimeter strip 14 to the building as illustrated in FIG.
12. The clip 16 is designed so as to interlock with the panel
perimeter strip 14 while holding the infill strip 38 (FIG. 10)
securely in place.
[0040] The system optionally includes a panel stiffener 18
component (FIG. 4), which may be used on large sized panels. The
stiffener 18 is used to prevent the popping or "oil canning" of the
panel. As the panel heats up, the panel expands and makes a popping
sound. The stiffener 18 reinforces the panel to reduce this
effect.
[0041] The panel stiffener 18 may comprise a hollow tube, as shown
in FIG. 4. An internally reinforced panel stiffener 18A, 18B may
alternatively be used for greater stability (see FIGS. 19, 20).
Where panel stiffeners are used, the panel perimeter strip may be
adapted to better locate and secure the stiffener component. A
panel perimeter strip 14A having profile as shown in FIG. 18 may be
advantageous for this purpose. The extended interior lip of the
panel perimeter strip operates to secure the panel stiffener
component.
[0042] Panel stiffeners may be provided in different sizes
depending on the wind pressures to which the panel will be exposed.
A larger width panel stiffener 18B may be advantageous where there
are greater wind loads on the panel system or if less deflection on
the panel is desired. It will be appreciated that the construction
of the panels also provides a basic level of rigidity and
stiffeners are not necessarily required.
[0043] As shown in FIG. 5, the aluminum composite material 20 (ACM)
consists of a core of low density polyethylene 24 sandwiched
between two sheets of aluminum 22 (each approximately 0.5 mm
thick). The finish face of the aluminum is coated with a
polyvinylidene fluoride coating. The inner aluminum layer is
typically coated with chrome or polyester coatings. The standard
thickness of the panel is 5/32'' (4 mm) but thickness may range
from 1/8'' (3 mm) to 1/4'' (6 mm), depending on customer preference
or structural requirements.
[0044] A finished ACM panel 32 may be fabricated from a flat sheet
of ACM 26 using different types of router and cutting bits 28 (FIG.
6). After the sheet of ACM has been cut and routed, it is then bent
along the router lines to form the finished panel 32 (FIG. 7). The
newly shaped panel 32 is then assembled with the panel perimeter
strip 14 using a panel rivet 36 to complete the finished panel
(FIG. 8). A standard panel rivet for this application is 3/16''
diameter.
[0045] There are various methods to accomplish the routing and
cutting process:
[0046] Method 1
[0047] Handheld router (not shown): A handheld router is used more
often when reworking a panel to a different size. This method
requires the simplest tool set up, but is the most labour-intensive
method of fabrication due to the lengthy time for setup and layout
of each different panel.
[0048] Method 2
[0049] Vertical table saw (not shown): A vertical table saw can
also be used, both to cut and rout the panels. Custom "V" routing
blades can be purchased to rout the panels. Panel design is limited
using the vertical table saw in itself. Using it in combination
with the hand held router has its advantages, but it is still a
costly way to manufacture panels.
[0050] Method 3
[0051] CNC-Machine (not shown): The computer numerically controlled
(CNC) machine is a complete and concise way to manufacture panels.
Once the panel has been designed by a CAD operator it is then sent
directly to the machine. This machine has been found to be very
useful and economical for manufacturing panels. This is the
applicants' preferred method for cutting and routing panels.
[0052] The infill strip (FIG. 9) is typically cut to a width of
approximately 11/4'' (32 mm) for a 1/2'' (13 mm) joint. The infill
strip replaces the conventional caulk joint, giving the panel
system a clean, maintenance free appearance. The infill strip also
is used to hide the fasteners 36 for the attachment clip (FIG.
10).
[0053] As shown in FIG. 11, to install the panel system, sub
framing is first constructed using two back-to-back galvanized
steel "L" angles 40 (FIG. 12); the two "L" angles allow the
installer to level the substrate in all 3 axes before installation
of panels. The sub framing is typically installed horizontally at
each horizontal joint as shown in FIG. 11. The method of
installation of the framing at its correct installation
measurements starts at the bottom of the substrate wall and moves
up, making sure that each row is level to the previous row
installed.
[0054] A layer of isolation tape 42 may be applied to the back of
aluminum attachment clips 16 (FIG. 3) to prevent direct contact
between the galvanized steel sub framing and the aluminum
attachment clip and thus prevent galvanic action (electrolytic
decay of the aluminum) over time. Preferably, stainless steel
self-drilling screws are used to fasten aluminum attachment clips
to steel sub framing 40. After determining a logical order of
installation, each panel is to be plumbed and leveled to ensure a
tight and concise fit form panel to panel.
[0055] Infill strip is preferably shipped in long lengths and are
to be cut to fit on site. The strips may have a protective plastic
coating, which is then removed from the face of the infill strips
before installing them. These infill strips can be installed one or
two ways:
[0056] First, as shown in FIGS. 13-15, the infill strips may be
slipped in before the adjacent panel is installed when the edge of
the joint is not accessible, or when the infill strip has a curve
or bend in it. The infill strip 38 is fitted into the space between
the panel 32 return and the attachment clips 14 as illustrated in
FIG. 13 and FIG. 14. Then an adjacent panel 32' is installed so
that the infill strip 38 and attachment clip 16 engage into the
slots in the panel edge at the perimeter strip 14' (FIG. 15).
[0057] As an alternative method of installation, the installer can
slide the infill strip 38 in from the end (FIG. 16), which allows
for a simplified installation of the panels. The infill strips are
not installed until an area is complete. This means that panels can
be adjusted for straightness and position even after adjacent
panels have been installed. The difficulty with this method is that
the end of the joint will not always be accessible (i.e. wall or
window frame) and the infill strip 38 may have a tendency to catch
on the attachment clips as it is being slid into the joint. To aid
in the sliding of the strip, a tool may be used to pull the leading
edge over the clips (not shown).
[0058] The finish faces of the panels may have a protective film 50
to protect against minor abrasions that may occur during handling
and installation. The protective film may be peeled back from the
returns of the panels before installing. To keep the panels clean
and free of construction debris, generally the protective plastic
film 50 is only removed from the faces of the panels once the
landscaping has been completed, as seen in FIG. 17.
[0059] The foregoing description illustrates only certain preferred
embodiments of the invention. The invention is not limited to the
foregoing examples. That is, persons skilled in the art will
appreciate and understand that modifications and variations are, or
will be, possible to utilize and carry out the teachings of the
invention described herein. Accordingly, all suitable
modifications, variations and equivalents may be resorted to, and
such modifications, variations and equivalents are intended to fall
within the scope of the invention as described and within the scope
of the claims.
* * * * *