U.S. patent application number 12/419034 was filed with the patent office on 2010-02-18 for wall panel joint apparatus and system using same.
This patent application is currently assigned to Lymo Construction Co., Inc.. Invention is credited to Dan Lynch, Kong K. Taing.
Application Number | 20100037549 12/419034 |
Document ID | / |
Family ID | 41680299 |
Filed Date | 2010-02-18 |
United States Patent
Application |
20100037549 |
Kind Code |
A1 |
Lynch; Dan ; et al. |
February 18, 2010 |
WALL PANEL JOINT APPARATUS AND SYSTEM USING SAME
Abstract
A wall panel joint apparatus and a system using same is
disclosed. The wall panel joint includes a perimeter joint body
having a predetermined size and shape. The perimeter joint body
floatably attaches to at least two wall panels. Embodiments include
where the wall panel joint includes one, two, or more chambers in
addition to the wall cavity. The system includes at least two wall
panel joints that attach the wall panels to an architectural wall.
At the point of intersection of the joints, the joints are mitered.
The system also includes a wall attachment device and a means for
attaching the joint to the wall attachment device. The system is
liquid water impermeable, air permeable, and water vapor permeable
system, providing a ventilated, waterproof wall panel attachment
joints for use in same.
Inventors: |
Lynch; Dan; (Bedford,
NH) ; Taing; Kong K.; (Allston, MA) |
Correspondence
Address: |
DEVINE, MILLIMET & BRANCH, P.A.
111 AMHERST STREET, BOX 719
MANCHESTER
NH
03105
US
|
Assignee: |
Lymo Construction Co., Inc.
Merrimack
NH
|
Family ID: |
41680299 |
Appl. No.: |
12/419034 |
Filed: |
April 6, 2009 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11336242 |
Jan 20, 2006 |
|
|
|
12419034 |
|
|
|
|
60645101 |
Jan 20, 2005 |
|
|
|
60655370 |
Feb 23, 2005 |
|
|
|
Current U.S.
Class: |
52/506.08 ;
52/745.13 |
Current CPC
Class: |
E04F 17/00 20130101;
E04F 13/0889 20130101; E04F 13/007 20130101 |
Class at
Publication: |
52/506.08 ;
52/745.13 |
International
Class: |
E04B 2/00 20060101
E04B002/00; E04B 1/00 20060101 E04B001/00 |
Claims
1. A wall panel system comprising: a plurality of wall panel units,
each unit having a wall panel and a plurality of perimeter clips;
each wall panel having a planar surface and a plurality of mounting
flanges, the mounting flanges generally perpendicular to the planar
surface; each perimeter clip including: a body; a panel flange
extending from the body, the panel flange adapted to engage with
one of the mounting flanges of one of the wall panels; and at least
a pair of strip flanges extending from the body, the at least a
pair of strip flanges and the body defining at least a pair of
pockets; a pair of filler strips associated with a pair of
perimeter clips of the plurality of perimeter clips, the filler
strips with the pair of perimeter clips defining a wall panel
joint, each of the filler strips having a pair of receiving edges,
each of the filler strips extending between adjacent perimeter
clips with a first receiving edge received in a pocket of one of
the perimeter clips and the second receiving edge received in a
pocket of the other perimeter clip, the pair of filler strips
defining a chamber interposed between the adjacent perimeter clips
and the filler strip for allowing pressure equalization while
minimizing water entry; and at least one attachment clip, the
attachment clip engaging a pair of the perimeter clips for
retaining the perimeter clips and the associated wall panel of the
wall panel unit.
2. A wall panel system of claim 1 wherein the plurality of mounting
flanges of each wall panel are four mounting flanges including a
top horizontal mounting flange, a bottom horizontal mounting
flange, and a pair of vertical mounting flanges; and each perimeter
clip is identical and mountable on vertical mounting flanges and
horizontal mounting flanges.
3. A wall panel system of claim 1 wherein each perimeter clip is
identical and the adjacent pair of perimeter clips with the filler
strips defining the wall panel joint, are positioned mirrored to
each other such that the pockets align with each other.
4. A wall panel system of claim 1 for securing to a wall of a
building further comprising at least one wall securing device
secured to the wall of the building, the at least one attachment
clip carried by the at least one wall securing device wherein the
wall panel units and the wall of the building define a wall cavity
having a pressure equal to the outside atmosphere while not
infiltrated by rain.
5. A wall panel system of claim 1 wherein the at least a pair of
strip flanges includes an outer strip flange projecting from the
body of the perimeter clip, the outer strip flange defines an "U"
shaped outer pocket of the at least a pair of pockets and the at
least a pair of strip flanges includes a middle strip flange and an
inner strip flange that project from the body of the perimeter
clip, the middle strip flange and the inner strip flange define an
"U" shaped inner pocket of the at least a pair of pockets.
6. A wall panel system of claim 5 wherein the middle strip flange
is interposed between the outer strip flange and the inner strip
flange, the inner strip flange having a varying thickness including
a main portion and a thinner projection portion that extends from
the main portion away from the body of the perimeter clip and a
protrusion that projects from the body and the main portion away
from the thinner projection portion.
7. A wall panel system of claim 6 wherein each perimeter clip is
identical and the adjacent perimeter clips are positioned mirrored
to each other such that the "U" shaped inner pockets align with
each other; the pair of filler strips including an inner filler
strip that is received by and extends between the "U" shaped inner
pockets of the adjacent perimeter clips; the thinner projection
portion and the inner filler strip define an arm receiving space
for receiving a portion of the at least one attachment clip.
8. A wall panel system of claim 7 wherein the attachment clip has a
pair of grooves for accepting the inner strip flange of one of the
perimeter clips wherein one of the perimeter clips is for holding
and supporting the weight of the perimeter clip and the wall panel
of the wall panel unit and the upper arm portion of the attachment
clip is received in the arm receiving space interposed for limiting
motion of the perimeter clip in a direction perpendicular to the
planar portion of the wall panel.
9. A wall panel system of claim 1 for securing to a wall of a
building further comprising: at least one wall securing device
secured to the wall of the building, the at least one attachment
clip carried by the at least one wall securing device wherein the
wall panel units and the wall of the building define a wall cavity;
the plurality of mounting flanges of each wall panel are four
mounting flanges including a top horizontal mounting flange, a
bottom horizontal mounting flange, and a pair of vertical mounting
flanges; the at least a pair of strip flanges of the perimeter clip
includes an outer strip flange, a middle strip flange, and an inner
strip flange, each flange projecting from the body of the perimeter
clip, the outer strip flange defines an "U" shaped outer pocket of
the at least a pair of pockets, the middle strip flange and the
inner strip flange define an "U" shaped inner pocket of the at
least a pair of pockets, the middle strip flange is interposed
between the outer strip flange and the inner strip flange, the
inner strip flange having a varying thickness including a main
portion and a thinner projection portion that extends from the main
portion away from the body of the perimeter clip and a protrusion
that projects from the body and the main portion away from the
thinner projection portion; and each perimeter clip is identical
and mountable on vertical mounting flanges and horizontal mounting
flanges of the wall panels, the adjacent pair of perimeter clips
with the filler strips defining the wall panel joint, are
positioned mirrored to each other such that the pockets align with
each other, wherein the outer flange has a tip flange portion that
extends further towards the other wall panel of the wall panel
joint than the respective mounting flange such that any water
entering the outer pocket will drain over the mounting flange
rather than enter the chamber.
10. A wall panel system of claim 1 wherein each of the perimeter
clips wherein the at least a pair of strip flanges includes at
least three strip flanges, wherein the at least a pair of pockets
being at least three pockets defined by the at least three strip
flanges and the body; the pair of filler strips includes at least
three filler strips, each of the filler strips having a pair of
receiving edges, each of the filler strips extending between
adjacent perimeter clips with a first receiving edge received in a
pocket of one of the perimeter clips and the second receiving edge
received in a pocket of the other perimeter clip; and the chamber
being at least two chambers wherein each chamber is interposed
between the adjacent perimeter clips and a pair of the at least
three filler strips for allowing pressure equalization while
minimizing water entry.
11. A wall panel system of claim 1 wherein: the at least a pair of
strip flanges extending from the body includes an outer strip
flange, a middle strip flange, and an inner strip flange, the outer
strip flange defining a "U" shaped outer pocket of the at least a
pair of pockets and the middle strip flange and the inner strip
flange defining a "U" shaped inner pocket of the at least a pair of
pockets; and the pair of filler strips includes an outer filler
strip extending between the "U" shaped outer pocket of an adjacent
perimeter clip and an inner filler strip extending between the "U"
shaped inner pocket of an adjacent perimeter clip, the outer filler
strip and the inner filler strip defining a chamber interposed
between the adjacent perimeter clips and the filler strip for
allowing pressure equalization while minimizing water entry.
12. A wall panel system of claim 1 wherein the wall panel system is
secured to a building having a wall structure, the wall panel
system wherein: the plurality of wall panel units includes at least
four wall panel units; the plurality of mounting flanges of each
wall panel is four mounting flanges including a top horizontal
mounting flange, a bottom horizontal mounting flange, and a pair of
vertical mounting flanges; each perimeter clip is identical and
mountable on vertical mounting flanges and horizontal mounting
flanges and the adjacent perimeter clips are positioned mirrored to
each other such that the pockets align with each other; at least
one wall securing device associated with a corner of the plurality
of wall panel units and secured to the wall structure of the
building, the at least one attachment clip carried by the at least
one wall securing device wherein the wall panel units and the wall
of the building define a wall cavity having a pressure equal to the
outside atmosphere while not infiltrated by rain.
13. A wall panel system of claim 12 wherein the at least a pair of
strip flanges of each of the perimeter clips includes at least
three strip flanges, wherein the at least a pair of pockets being
at least three pockets defined by the at least three strip flanges
and the body; the pair of filler strips includes at least three
filler strips, each of the filler strips having a pair of receiving
edges, each of the filler strips extending between adjacent
perimeter clips with a first receiving edge received in a pocket of
one of the perimeter clips and the second receiving edge received
in a pocket of the other perimeter clip; and the chamber being at
least two chambers wherein each chamber is interposed between the
adjacent perimeter clips and a pair of the at least three filler
strips for allowing pressure equalization while minimizing water
entry.
14. A wall panel joint comprising: a pair of perimeter clips, each
perimeter clip including: a body; a panel flange extending from the
body, the panel flange adapted to engage with one of the mounting
flanges of one of the wall panels; and at least a pair of strip
flanges extending from the body, the at least a pair of strip
flanges and the body defining at least a pair of pockets; a pair of
filler strips, each of the filler strips having a pair of receiving
edges, each of the filler strips extending between adjacent
perimeter clips with a first receiving edge received in a pocket of
one of the perimeter clips and the second receiving edge received
in a pocket of the other perimeter clip, the pair of filler strips
defining a chamber interposed between the adjacent perimeter clips
and the filler strips for allowing pressure equalization while
minimizing water entry.
15. A wall panel joint of claim 14 wherein each perimeter clip is
identical and the adjacent perimeter clips are positioned mirrored
to each other such that the pockets align with each other.
16. A wall panel joint of claim 15 further comprising at least one
attachment clip, the attachment clip engaging a pair of the
perimeter clips for retaining the perimeter clips.
17. A wall panel joint of claim 16 further comprising a plurality
of wall panels units, each unit having a wall panel and a plurality
of the perimeter clips, each wall panel having a planar surface and
a plurality of mounting flanges, the mounting flanges generally
perpendicular to the planar surface.
18. A wall panel joint of claim 17 wherein the wall panel system is
secured to a building having a wall structure, the wall panel
system wherein: the plurality of wall panel units includes at least
four wall panel units; the plurality of mounting flanges of each
wall panel is four mounting flanges including a top horizontal
mounting flange, a bottom horizontal mounting flange, and a pair of
vertical mounting flanges; each perimeter clip is identical and
mountable on vertical mounting flanges and horizontal mounting
flanges and the adjacent perimeter clips are positioned mirrored to
each other such that the pockets align with each other; and at
least one wall securing device is associated with a corner of the
plurality of wall panel units and secured to the wall structure of
the building, the at least one attachment clip carried by the at
least one wall securing device wherein the wall panel units and the
wall of the building define a wall cavity having a pressure equal
to the outside atmosphere while not infiltrated by rain.
19. A method of installing a wall panel system comprising:
providing a building having a wall structure; providing a plurality
of wall panel units, each unit having a wall panel and four
perimeter clips; each wall panel having a planar surface and four
mounting flanges, the mounting flanges generally perpendicular to
the planar surface; and each perimeter clip including: a body; a
panel flange extending from the body, the panel flange adapted to
engage with one of the mounting flanges of one of the wall panels;
and at least a pair of strip flanges extending from the body, the
at least a pair of strip flanges and the body defining at least a
pair of pockets; mounting a plurality of wall securing devices to
the wall structure of the building, the wall securing devices
positioned on the wall structure such that there is at least one
wall securing device associated with each corner of each of the
plurality of wall panel units: mounting a plurality of attachment
clips to the perimeter clip associated with the top horizontal
mounting flange of the wall panel of at least one of the plurality
of the wall panel units by securing a pair of grooves on the
attachment clip around an inner strip flange of the at least a pair
of strip flanges of the perimeter clip; mounting a plurality of
attachment clips to the wall securing device located in proximity
to where the bottom horizontal mounting flange of the wall panel of
at least one of the plurality of the wall panel units is to be
located; positioning the perimeter clip of the bottom horizontal
mounting flange of the wall panel of at least one of the plurality
of the wall panel units such that the plurality of attachment clips
mounted to the wall securing device have an upper arm portion
located in an arm receiving space defined by the inner strip flange
of the perimeter clip and a filler strip; securing the plurality of
attachment clips to the perimeter clip associated with the top
horizontal mounting flange of the wall panel of at least one of the
plurality of the wall panel units to the associated plurality of
wall securing devices mounted to the wall structure of the
building; positioning a pair of filler strips with at least one of
the perimeter clips of at least one of the plurality of the wall
panel units; repeating the mounting of a plurality of wall securing
devices, mounting a plurality of attachment clips, positioning the
perimeter clip, and securing the plurality of attachment clips
until the wall panel system is completely secured to the building
with defining a wall panel joint that has at least one chamber
interposed between the adjacent perimeter clips and the filler
strips for allowing pressure equalization while minimizing water
entry.
20. A method of installing a wall panel system of claim 19 wherein
each of the perimeter clips wherein the at least a pair of strip
flanges includes at least three strip flanges, wherein the at least
a pair of pockets being at least three pockets defined by the at
least three strip flanges and the body; the pair of filler strips
includes at least three filler strips, each of the filler strips
having a pair of receiving edges, each of the filler strips
extending between adjacent perimeter clips with a first receiving
edge received in a pocket of one of the perimeter clips and the
second receiving edge received in a pocket of the other perimeter
clip; and the chamber being at least two chambers wherein each
chamber is interposed between the adjacent perimeter clips and a
pair of the at least three filler strips for allowing pressure
equalization while minimizing water entry.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part
application of U.S. patent application Ser. No. 11/336,242 filed on
Jan. 20, 2006 which claims the benefit of Provisional Patent
Application Ser. No. 60/645,101 filed Jan. 20, 2005 and Provisional
Patent Application Ser. No. 60/655,370 filed Feb. 23, 2005, which
are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to wall panel joints and
systems for wall panel application.
BACKGROUND INFORMATION
[0003] Architectural panel has been in use for many years. All
architectural panel systems can be classified into two major
categories, namely, "face-sealed" and "vented rainscreen"
systems.
[0004] Face-sealed systems include all systems with joinery that
make use of sealant in the joinery whereby the system is
substantially impermeable to either water or air. Achieving
complete face seal is the very basis of all face seal systems.
Sealant can be caulking, gasket, or another sealant of similar
function. However, the lack of permeability/venting to either water
vapor or air makes this system problematic.
[0005] On the contrary, vented rainscreen systems are designed to
allow for permeability through the joinery, known as vents. The
vents allow for breathability and rapid pressure equalization
within the system cavity. However, these systems allow water to
penetrate, causing water damage which is also problematic.
[0006] Unfortunately, there are deficiencies in conventional wall
panel systems that lead to water damage and/or lack of venting
capability. Furthermore, the systems have numerous distinct
components that are required to build the conventional wall panel
systems.
SUMMARY
[0007] In contrast to the above-described wall panel systems, the
instant system has a symmetric panel structure with a wall panel
joint having a pair of perimeter clips and at least two filler
strips defining at least one chamber in addition to a wall cavity.
The chamber provides for pressure equalization by increasing the
air pressure within the chamber until it equals the applied wind
pressure. Furthermore, the configuration of the flange portion of
the outer strip flange projecting higher like the mounting flange
results in blocking water. When the pressures are equal, water
cannot enter the chamber. This state is attained quickly. Thus, the
wall panel joints allow the wall panel system to attain optimal
ventilation within the system, but prevent and minimize water
entry. Furthermore, the system in addition to the pressure
equalization chamber provides an internal gutter system and allows
for thermal movement between adjacent wall panel units.
[0008] One embodiment is directed to a wall panel system which
includes a plurality of wall panel units. Each wall panel unit has
a wall panel and a plurality of perimeter clips. Each wall panel
has a planar surface and a plurality of mounting flanges. The
mounting flanges are generally perpendicular to the planar
surface.
[0009] Each perimeter clip includes a body and a panel flange
extending from the body. The panel flange is adapted to engage with
one of the mounting flanges of one of the wall panels. The
perimeter clips have at least a pair of strip flanges extending
from the body. The strip flanges and the body define at least a
pair of pockets. An attachment clip engages a pair of the perimeter
clips for retaining the perimeter clips and the associated wall
panel of the wall panel unit.
[0010] A pair of filler strips is associated with a pair of
perimeter clips of the plurality of perimeter clips. The filler
strips with the pair of perimeter clips define a wall panel joint.
Each of the filler strips has a pair of receiving edges. Each of
the filler strips extends between adjacent perimeter clips with a
first receiving edge received in a pocket of one of the perimeter
clips and the second receiving edge received in a pocket of the
other perimeter clip. The pair of filler strips defines a chamber
interposed between the adjacent perimeter clips and the filler
strip for allowing pressure equalization while minimizing water
entry into the wall cavity.
[0011] In some arrangements, the mounting flanges of each wall
panel are four mounting flanges including a top horizontal mounting
flange, a bottom horizontal mounting flange, and a pair of vertical
mounting flanges. Each perimeter clip is identical and mountable on
vertical mounting flanges and horizontal mounting flanges.
[0012] In an embodiment, each perimeter clip is identical and the
adjacent pair of perimeter clips, the pair of perimeter clips, with
the filler strips define the wall panel joint. The perimeter clips
are positioned mirrored to each other such that the pockets align
with each other.
[0013] In an embodiment, the wall panel system for securing to a
wall of a building includes at least one wall securing device
secured to the wall of the building. The attachment clip is carried
by the at least one wall securing device wherein the wall panel
units and the wall of the building define a wall cavity having a
pressure equal to the outside atmosphere while not infiltrated by
rain.
[0014] In an embodiment, the pair of strip flanges includes an
outer strip flange, a middle strip flange, and an inner strip
flange projecting from the body of the perimeter clip. The outer
strip flange defines an "U" shaped outer pocket of the pockets. The
middle strip flange and the inner strip flange define an "U" shaped
inner pocket of the at least a pair of pockets.
[0015] In some arrangements, a middle strip flange is interposed
between the outer strip flange and the inner strip flange. The
inner strip flange has varying thickness including a main portion
and a thinner projection portion that extends from the main portion
away from the body of the perimeter clip. A protrusion of the inner
strip flange projects from the body and the main portion projects
away from the thinner projection portion.
[0016] In some arrangements, each perimeter clip is identical and
the adjacent perimeter clips are positioned mirrored to each other
such that the "U" shaped inner pockets align with each other. The
pair of filler strips includes an inner filler strip that is
received by and extends between the "U" shaped inner pockets of the
adjacent perimeter clips. The thinner projection portion and the
inner filler strip define an arm receiving space for receiving an
upper arm portion of the at least one attachment clip.
[0017] In an embodiment, the attachment clip has a pair of grooves
for accepting the inner strip flange of one of the perimeter clips
wherein one of the perimeter clips is for holding and supporting
the weight of the perimeter clip and the wall panel of the wall
panel unit. The upper arm portion of the attachment clip is
received in the arm receiving space interposed between the filler
strip and thinner projection of the flange for limiting motion of
the perimeter clip in a direction perpendicular to the planar
portion of the wall panel.
[0018] In an embodiment, the adjacent mounting flanges of the
adjacent wall panel and the outer filler strip define a gutter
channel for channeling water.
[0019] In an embodiment, each perimeter clip is identical and
mountable on vertical mounting flanges and horizontal mounting
flanges of the wall panels. The adjacent pair of perimeter clips
with the filler strips defining the wall panel joint, are
positioned mirrored to each other such that the pockets align with
each other. The outer flange has a tip flange portion that extends
further towards the other wall panel of the wall panel joint than
the respective mounting flange such that any water entering the
outer pocket will drain over the mounting flange rather than enter
the chamber.
[0020] In an embodiment, the perimeter clip has at least three
strip flanges and at least three pockets defined by the at least
three strip flanges and the body. There are at least three filler
strips. Each of the filler strips has a pair of receiving edges.
Each of the filler strips extends between adjacent perimeter clips
with a first receiving edge received in a pocket of one of the
perimeter clips and the second receiving edge received in a pocket
of the other perimeter clip. There are at least two chambers
wherein each chamber is interposed between the adjacent perimeter
clips and a pair of the at least three filler strips for allowing
pressure equalization while minimizing water entry.
[0021] In an arrangement, the at least one pair of strip flanges
extending from the body includes an outer strip flange, a middle
strip flange, and an inner strip flange. The outer strip flange
defines a "U" shaped outer pocket. The middle strip flange and the
inner strip flange define a "U" shaped inner pocket. The pair of
filler strips includes an outer filler strip extending between the
"U" shaped outer pocket of an adjacent perimeter clip and an inner
filler strip extending between the "U" shaped inner pocket of the
adjacent perimeter clip. The outer filler strip and the inner
filler strip define a chamber interposed between the adjacent
perimeter clips and the filler strip for allowing pressure
equalization while minimizing water entry.
[0022] In an arrangement, the wall panel system is secured to a
building having a wall structure. The plurality of wall panel units
includes at least four wall panel units. Each wall panel has four
mounting flanges including a top horizontal mounting flange, a
bottom horizontal mounting flange, and a pair of vertical mounting
flanges. Each perimeter clip is identical and mountable on vertical
mounting flanges and horizontal mounting flanges. The adjacent
perimeter clips are positioned mirrored to each other such that the
pockets align with each other. A wall securing device is associated
with a corner of each of the plurality of wall panel units and is
secured to the wall structure of the building. An attachment clip
is carried by each of the wall securing devices wherein the wall
panel units and the wall of the building define a wall cavity
having a pressure equal to the outside atmosphere while not
infiltrated by rain.
[0023] In an embodiment, a wall panel joint includes a pair of
perimeter clips and a pair of filler strips. Each perimeter clip
includes a body, a panel flange extending from the body, and at
least a pair of strip flanges. The panel flange is adapted to
engage with one of the mounting flanges of one of the wall panels.
The strip flanges and the body define at least a pair of pockets.
Each of the filler strips has a pair of receiving edges. Each of
the filler strips extends between adjacent perimeter clips with a
first receiving edge received in a pocket of one of the perimeter
clips and the second receiving edge received in a pocket of the
other perimeter clip. The pair of filler strips defines a chamber
interposed between the adjacent perimeter clips and the filler
strips for allowing pressure equalization while minimizing water
entry.
[0024] In one embodiment, a method of installing a wall panel
system includes providing a plurality of wall panel units. Each
unit has a wall panel and four perimeter clips. Each wall panel has
a planar surface and four mounting flanges. The mounting flanges
are generally perpendicular to the planar surface.
[0025] A plurality of wall securing devices are mounted to the wall
structure of the building. The wall securing devices are positioned
on the wall structure such that there is at least one wall securing
device associated with each corner of each of the plurality of wall
panel units. A plurality of attachment clips are mounted to the
perimeter clip associated with the top horizontal mounting flange
of the wall panel of at least one of the wall panel units by
securing a pair of grooves on the attachment clip around an inner
strip flange of the at least a pair of strip flanges of the
perimeter clip. A plurality of attachment clips are mounted to the
wall securing device located in proximity to where the bottom
horizontal mounting flange of the wall panel of at least one of the
wall panel units is to be located. The perimeter clip of the bottom
horizontal mounting flange of the wall panel of at least one of the
wall panel units is positioned such that the plurality of
attachment clips mounted to the wall securing device have an upper
arm portion located in an arm receiving space defined by the inner
strip flange of the perimeter clip and a filler strip.
[0026] The plurality of attachment clips are secured to the
perimeter clip associated with the top horizontal mounting flange
of the wall panel of at least one of the plurality of the wall
panel units to the associated plurality of wall securing devices
mounted to the wall structure of the building.
[0027] A pair of filler strips is positioned with at least one of
the perimeter clips of at least one of the wall panel units. The
steps of mounting of a plurality of wall securing devices, mounting
a plurality of attachment clips, positioning the perimeter clip and
the securing the plurality of attachment clips are repeated until
the wall panel system is completely secured to the building with a
wall panel joint that has at least one chamber interposed between
the adjacent perimeter clips and the filler strips allowing
pressure equalization while minimizing water entry.
[0028] These aspects of the invention are not meant to be exclusive
and other features, aspects, and advantages of the present
invention will be readily apparent to those of ordinary skill in
the art when read in conjunction with the appended claims and
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] These and other features and aspects of the present
invention will be better understood by reading the following
detailed description of preferred embodiments, taken together with
the drawings wherein:
[0030] FIG. 1 is a break-away front view of a single chamber in
addition to a wall cavity embodiment of a wall panel system of the
present invention;
[0031] FIG. 2 is a horizontal sectional view showing a vertical
joint of the single chamber embodiment of FIG. 1 of the present
invention;
[0032] FIG. 3 is a sectional view of one embodiment of a horizontal
joint of the single chamber embodiment of FIG. 1 of the present
invention;
[0033] FIG. 4A is a front view showing the relationship of adjacent
wall panel units;
[0034] FIG. 4B is an enlarged section of four adjacent wall panel
units taken along the area 4B in FIG. 4A;
[0035] FIG. 5 is an illustration of the flow of air through the
vertical joint according to one embodiment of the present
invention;
[0036] FIG. 6 is a sectional view of a vertical joint of an
alternative single chamber embodiment;
[0037] FIG. 7 is a sectional view of one embodiment of a double
chamber vertical joint embodiment of the present invention; and
[0038] FIG. 8 is a sectional view of one embodiment of the double
chamber horizontal joint embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0039] A wall panel system that has a symmetric panel structure
with a wall panel joint having a pair of perimeter clips and at
least two filler strips defining at least one chamber in addition
to a wall cavity. The chamber provides for pressure equalization by
increasing the air pressure within the chamber until it equals the
applied wind pressure. When the pressures are equal, water cannot
enter the chamber. This state is attained quickly. Furthermore, the
configuration of the flange portion of the outer strip flange
projecting higher like the mounting flange results in blocking
water. Thus, the wall panel joints allow the wall panel system to
attain optimal ventilation within the system, but prevent and
minimize water entry. Furthermore, the system, in addition to the
pressure equalization chamber, provides an internal gutter system
and allows for thermal movement between adjacent wall panel
units.
[0040] Referring to FIG. 1, a portion of a wall panel system 20 is
shown. The wall panel system 20 has a plurality of wall panel units
22. Each wall panel unit 22 includes a wall panel 24 and a
plurality of perimeter clips 26. In addition, the wall panel system
20 includes a plurality of filler strips 28 and at least one
attachment clip 30 and a wall securing device 32.
[0041] Still referring FIG. 1, each wall panel 24 has a planar
portion 34 and plurality of mounting flanges 36. In a preferred
embodiment, there is a perimeter clip 26 associated with each of
the mounting flanges 36 of the wall panel 24. Each wall panel unit
22 consists of a wall panel 24 and the four associated perimeter
clips 26. In the preferred embodiment, the perimeter clips 26 are
mitered and engage each other at the corners of the wall panel
24.
[0042] Still referring to FIG. 1, portions of four wall panel units
22 are shown. Each wall panel unit 22 typically interacts with four
adjoining wall panel units 22 and in addition is diagonally
adjacent to four additional wall panel units 22. Adjoining wall
panel units 22 have parallel mounting flanges 36 wherein the
adjoining perimeter clips 26 and the filler strips 28 form a wall
panel joint 40. In FIG. 1, the wall panel unit 22a is adjoining
wall panel units 22b and 22c with filler strips 28 extending
between the units 22 respective perimeter clips 26 as explained in
greater detail below. Wall panel unit 22d is adjacent to wall panel
22a.
[0043] In one embodiment, the wall panels 24 are made of an
aluminum composite material (ACM) that has two sheets of
prefinished 0.020'' aluminum (85% recycled content) bonded to a
low-density polyethylene core. The perimeter clips 26 are extruded
and made of aluminum alloy such as 6061 aluminum. The filler strips
28 are made of either ACM or a contrasting material. The attachment
clip 30 and the wall securing device 32 are made of aluminum alloy.
It is recognized that other metals and materials can be used
including zinc, copper, stainless steel, and titanium.
[0044] Referring to FIG. 2, a horizontal sectional view of the wall
panel system 20 is shown. The wall panel joint 40 of two adjoining
wall panel units 22 is shown. The wall panel 24 has the planar
portion 34 and a mounting flange 36. The two perimeter clips 26
shown are identical. Each perimeter clip 26 has a body 42 and a
panel flange 44 which extends from the body 42. The panel flange 44
forms a right angle to engage the planer portion 34 and the
mounting flange 36 of the wall panel 24. The panel flange 44 can be
attached in many ways to the wall panel 24 including by rivets 46
as shown in FIG. 2. It is recognized, however that other methods
including adhesives and spot welding can be used to secure the
panel flange of the perimeter clip 26 to the wall panel 24.
[0045] In addition, the perimeter clip 26 has an outer strip flange
48. The outer strip flange 48 forms a "U" shaped outer pocket 50.
The perimeter clip 26 also has a middle strip flange 52 and an
inner strip flange 54. The middle strip flange 52 and the inner
strip flange 54 form a "U" shaped inner pocket 56.
[0046] Still referring to FIG. 2, the filler strips 26 include an
inner filler strip 58 and an outer filler strip 60. In the
embodiment shown, the inner filler strip 58 and the outer filler
strip 60 are identical in material but have different widths. The
different widths assist in forming an internal gutter. The filler
strips 60 and 58 each have a pair of receiving edges 62. The
receiving edges 62 of the filler strips 60 and 58 are received by
the "U" shaped pockets 50 and 56 to span between the perimeter
clips 26 of adjacent wall panel units 22. The filler strips 28, the
inner filler strip 58 and the outer filler strip 60, in conjunction
with the associated perimeter clips 26 define a chamber 64. The
chamber or pocket 64 is designed for ventilation and thermal
movement. This chamber 64 allows for pressure equalization and
permeability through impermeable material as explained further with
respect to FIG. 5. The adjacent perimeter clips 26, the inner
filler strip 58, and the outer filler strip 60 form a wall panel
joint 40.
[0047] Still referring to FIG. 2, the outer strip flange 48 and the
middle strip flange 52 each have a tip flange portion 68 that
projects into the chamber 64 from the remainder of the flange at an
angle .alpha. and .beta. respectively. The angles range from
between 10 degrees and 60 degrees and assist in positioning the
filler strips 28 during installation of the wall panel system 20 on
a building. In the embodiment shown, angle .alpha. is set at
approximately 15.degree. and .beta. is approximately 60.degree..
The dash lines represent edges of the perimeter clip 26 and the
wall panel 24 spaced from the section.
[0048] The wall joint 40 includes the pair of perimeter clips 26
and the filler strips 28. The perimeter clips 26, while identical,
have one of the adjoining or adjacent clips 26 flipped such that
the perimeter clips 26 mirror each other. The wall joint 40 is
symmetrical about an axis that is perpendicular to the filler
strips 28; the axis extends up and down in FIG. 2.
[0049] Referring to FIG. 3, a vertical section of the wall panel
system 20 is shown. As indicated above, each wall panel unit 22 in
the embodiment shown has four perimeter clips 26. While FIG. 3 show
different perimeter clips 26 than those shown in FIG. 2 in that
these perimeter clips run horizontally in contrast to vertically,
the perimeter clips 26 are identical in configuration. The person
assembling the wall panel units 22 does not need to stock two
styles of the perimeter clip.
[0050] The perimeter clips 26 have the panel flange 44 for securing
to the wall panel 24. The panel flange 44 forms a right angle to
engage the planer portion 34 and the mounting flange 36 of the wall
panel 24. The perimeter clip 26 has the outer strip flange 48 to
form the "U" shaped outer pocket 50. The middle strip flange 52 and
an inner strip flange 54 of the perimeter clip 26 form the "U"
shaped inner pocket 56.
[0051] Still referring to FIG. 3, the receiving edges 62 of the
filler strips 58 and 60 are received by the "U" shaped pockets 50
and 56 to span between the perimeter clips 26 of adjacent wall
panel units 22. The filler strips 28, the inner filler strip 58 and
the outer filler strip 60, in conjunction with the associated
perimeter clips 26 define the chamber 64.
[0052] Still referring to FIG. 3, the inner strip flange 54 of the
perimeter clip 26 has varying thickness and includes a main portion
72, a thinner projection portion 74, and a protrusion 76. The
protrusion 76 extends in the other direction from the body 42 of
the perimeter clip 26 than the rest of the inner strip flange 54.
Because of the differences in thickness between the main portion 72
and the thinner projection portion 74, an arm receiving space 78,
as best seen in FIG. 2, is created between the inner filler strip
58 and the thinner projection portion 74. The attachment clip 30,
also referred to as a rainscreen clip in the parent application,
has a central portion 80, an upper arm portion 82, and a lower "C"
channel portion 84. The central portion 80 has an opening for
receiving a fastener 88, such as a zinc coated screw, to attach the
attachment clip 30 to the wall securing device 32.
[0053] The upper arm portion 82 of the attachment clip 30 is
received in the arm receiving space 76 defined by the thinner
projection portion 74 of the inner strip flange 54 and the outer
filler strip 60. The "C" channel portion 84 of the attachment clip
30 has a pair of grooves 90 that receives the protrusion 76 and the
top of the thinner projection 74 of the outer strip flange 48 of
the perimeter clip 26.
[0054] The flange portion 68 of the outer strip flange 48 projects
higher than the mounting flange 36. Therefore, if any water works
its way into the "U" shaped pocket 50, the water will drain out
over the mounting flange 36 rather than enter the chamber 64.
[0055] Still referring to FIG. 3, the top portion of the wall panel
unit 22, which is shown in the lower half of the FIG, hangs from
the "C" channel portion 84 of the attachment clip 30. The lower
portion of the wall panel unit 22, which is shown in the upper half
of the FIG., is retained by positioning the upper arm portion 82 of
the attachment clip 30 in the arm receiving space 78. The arm
receiving space 78 is best seen in FIG. 2.
[0056] The wall securing device 32 is attached to a wall structure
92 of a building 94 and secures the perimeter clip 26 to the wall
structure 92 by connecting the attachment clip 30 to the wall
securing device 32. Although in the exemplary embodiment, the wall
securing device 32 is a subgirt, in other embodiments, any device
capable of securing the wall panel joint 40 to the wall structure
92 can be used.
[0057] The perimeter clip 26 floats on the attachment clip 30 to
allow for free movement in response to thermal expansion. The
attachment clip 30 is made from the same material as the perimeter
clip 26.
[0058] Although the terms "horizontal" and "vertical" are used
herein, the terms are merely used for distinction purposes. In some
embodiments, the horizontal joint can be used in both the
horizontal and vertical joint in the system. Following, both
vertical and horizontal joints can be attached to a wall securing
device. When the horizontal joints are used as both the vertical
and horizontal joints in the system, the horizontal joint is thus
representative of both joints in the system.
[0059] Referring to FIG. 4A, a front view showing the relationship
of nine adjacent wall panel units is shown. The wall panel unit 22a
is adjoining wall panel units 22b, 22c, 22e, and 22f with filler
strips 28 extending between the units 22 respective perimeter clips
26, as seen in FIGS. 1-3. Wall panel units 22d, 22g, 22h, and 22l
are adjacent to wall panel 22a in that they are diagonal to the
wall panel 22a. Whether vertical and horizontal joints are used in
the system, or just horizontal joints, the joints aligned spatially
vertically and horizontally intersect. This is the point of
intersection. The joints are mitered, thus, the point of
intersection forms a completely sealed corner.
[0060] Referring to FIG. 4B, an enlarged section of the
relationship of four adjacent wall panel units 22a, 22b, 22c, and
22d is shown. The filler strip 60 intersects to close the gap.
Whether vertical and horizontal joints are used in the system, or
just horizontal joints, the joints spatially aligned vertically and
horizontally intersect. This is the point of intersection. The
joints are mitered, thus, the point of intersection forms a
completely sealed corner.
[0061] As an example of installing the wall panel system 20, a
plurality of 8 feet by 16 feet wall panel units 20 are mounted as
the skin of a building. Each wall panel unit 20 has a wall panel 24
that is 8 feet high and 16 feet in length. The rectangular wall
panel 24 has a perimeter clip 26 mounted on each edge to the
mounting flange 36 as seen in FIG. 3. The mounting flanges, the
four mounting flanges 36, of each wall panel unit 20 are the top
horizontal flange, a bottom horizontal flange, and a pair vertical
flanges. Each perimeter clip is identical and mountable on vertical
flanges and horizontal flanges.
[0062] A series of wall securing devices 32 are secured to the
building near ground level spaced apart based upon the structure of
the building, but typically 4 to 8 feet apart. An attachment clip
30 is secured to each of the wall securing devices 32 using a
fastener 88.
[0063] A series of attachment clips 30 are secured to the inner
strip flange 54 at the top of the wall panel unit 22 by the "C"
channel portion 84 engaging the thinner projection 74 and the
protrusion 76. In one embodiment, the attachment clips 30 are
attached to the perimeter clip 26 prior to the perimeter clip 26
being secured to the wall panel 24. This wall panel 24 with the
four perimeter clips 26 is mitered and sealed at the job site with
attachment clips 30 on one edge, the top edge. The wall panel unit
22, such as 22a in FIG. 4A, is positioned next to the building with
the thin projection 74 of the attachment clip 30, which is already
secured to the building slipped into the arm receiving space 78 on
the perimeter clip 26 on the lower edge of the panel unit 22. These
attachment clips 30, as seen in FIG. 3, that are below the wall
panel unit 22 retain the wall panel unit 22 and limit movement of
the wall panel unit 22 in a direction perpendicular to the planar
portion 34. The series of attachment clips 30 that are already
secured to the top of the wall panel unit 22 are secured to the
wall securing devices 32 that are already secured to the wall
structure 92 of the building 94. The attachment clip 30, as seen in
FIG. 3, that is above the wall panel unit 22, supports the weight
and holds the wall panel unit 22 including the wall panel 24 and
the perimeter clip 26.
[0064] The adjacent panels both vertically and horizontally, such
as 22e and 22f in FIG. 4A, can be positioned next to the building
and secured. The filler strips 28 are positioned in the proper
pocket 50 or 56. The vertical filler strips 28 are installed
between two adjacent already mounted wall panel units 22. The
horizontal filler strips 28 are slipped in after the adjacent panel
units 22 are secured.
[0065] The process is continued until the entire wall panel system
20 is built. As indicated above, the purpose of the wall panel
system 20 is to allow pressure equalization between the outside
environment 116 and the wall cavity 114, as best seen in FIG. 5,
but prevent and minimize water entry into the wall cavity 114. The
chamber 64 provides for pressure equalization by increasing the air
pressure within the chamber until it equals the applied wind
pressure. When the pressures are equal, water cannot enter the
chamber.
[0066] The length and width of the joints will vary depending on
the architectural structure in which they are being used to hold
wall panels. Thus, the joints can be any length or width
desired.
[0067] Referring now to FIG. 5, the vertical joint shown in FIG. 2
is shown along with an illustration of the flow of air through the
joint. The arrows represent the air. The air 110 is blasted against
the wall panels 24. The wall panel joint 40 of the wall panel
system 20 defines a gutter channel 112 between the mounting flanges
36 of adjacent wall panels 24 and the outer filler strip 60. The
air enters the wall panel joint 40 through the gutter channel 112.
The air flows around the outer filler strip 60 in the "U" shaped
outer pocket 50 and into the chamber or compartment 64. The air
continues to flow around the inner filler strip 58 in the "U"
shaped inner pocket 56 and into the wall cavity 114.
[0068] A gap 66 is formed between the receiving edge 62 of each of
the respective filler strips 58, 60 and the "U" shaped pocket 50
and 56 of the perimeter clips 26. This gap 66 is designed for
ventilation and thermal movement. These gaps 66 allow for pressure
equalization and permeability through impermeable material.
[0069] In practice, kinetic energy (wind) will increase the air
pressure within the chamber until it equals the applied wind
pressure. When the pressures are equal, water cannot enter the
chamber. This state is attained quickly. Thus, the joints allow the
system to attain optimal ventilation within the system, but prevent
and minimize water entry. The joints shown in FIGS. 2 and 3 include
a number of mechanisms that both promote ventilation and prevent
water from reaching the architectural structure wall (shown as 92
in FIG. 6). In addition to the pressurize equalization, the flange
portion 68 of the outer strip flange 48 projects higher than the
mounting flange 36, as best seen in FIG. 3, and prevents water
entry.
[0070] Referring to FIG. 6, a sectional view of a vertical joint of
an alternative single chamber embodiment of the wall panel system
20 is shown. The wall panel joint 40 of two adjoining wall panel
units 22 is shown. The wall panel 24 has the planar portion 34 and
the mounting flange 36. The two perimeter clips 26 shown are
identical. Each perimeter clip 26 has the body 42 and the panel
flange 44 which extends from the body 42. The panel flange 44 forms
a right angle to engage the planer portion 34 and the mounting
flange 36 of the wall panel 24. The panel flange 44 can be attached
in many ways to the wall panel 24 including by rivets 46.
[0071] In addition, the perimeter clip 26 has the outer strip
flange 48 which forms the "U" shaped outer pocket. The perimeter
clip 26 also has the middle strip flange 52 and the inner strip
flange 54 which forms the "U" shaped inner pocket 56.
[0072] Still referring to FIG. 6, the filler strips 26 include the
inner filler strip 58 and the outer filler strip 60. In the
embodiment shown, the inner filler strip 58 and the outer filler
strip 60 are identical in material but have different widths. The
filler strips 60 and 58 each have a pair of receiving edges. The
receiving edges of the filler strips 58 and 60 are received by the
"U" shaped pockets 50 and 56 to span between the perimeter clips 26
of adjacent wall panel units 22. The filler strips 28, the inner
filler strip 58 and the outer filler strip 60, in conjunction with
the associated perimeter clips 26 define the chamber 64. The
chamber 64 is designed for ventilation and thermal movement. This
chamber 64 allows for pressure equalization and permeability
through impermeable material as explained above with respect to
FIG. 5. The adjacent perimeter clips 26, the inner filler strip 58,
and the outer filler strip 60 form the wall panel joint 40.
[0073] Still referring to FIG. 6, the wall panel system 20 has an
attachment clip 118 which has an arm portion 120 that is receivable
in the arm receiving space 76 defined by the thinner projection
portion 74 of the inner strip flange 54 and the outer filler strip
60. In contrast to the attachment clip 30 described above with
respect to FIG. 3, this attachment clip 118 is not required to
support the weight of the wall panel unit 22, but retain it against
the wall structure 92. Therefore the attachment clip 118 has only
one groove 122 that receives the protrusion 76 of the outer strip
flange 48 of the perimeter clip 26. The attachment clip 30 has a
central portion 124 that has an opening 126 for receiving a
fastener 88, such as a zinc coated screw, to attach the attachment
clip 118 to the wall securing device 32.
[0074] Referring now to FIGS. 7 and 8, an alternative embodiment of
the wall panel system 130 is shown. The system has a plurality of
perimeter clips 132 that each have a third "U" shaped pocket 134
for receiving a third, extreme inner filler strip 136. In the
embodiment shown in FIGS. 7 and 8, the third "U" shaped pocket 134
is formed by a projecting flange 140 that extends from the panel
flange 44. The projecting flange 140 has a pair of legs 142 and
144. The outer leg 142 is similar in shape to the middle strip
flange 52 and the inner leg 144 is similar in shape to the inner
strip flange 54. The inner leg 144 has a main portion 72, a thinner
projection portion 74, and a protrusion 76.
[0075] The pair of adjacent perimeter clips 132 in conjunction with
the inner filler strip 58 and the extreme inner filler strip 136
forms a second chamber 146.
[0076] Although embodiments showing wall panel joints having 2 and
3 filler strips 28 are shown, the invention includes wall panel
joints having two or more filler strips 28 and one or more
chambers. Although not shown in the exemplary embodiment, the
perimeter clip body can have more than two chambers. For each
filler strip added to the joint, a chamber is formed. It is
recognized that the perimeter clips need to be modified to include
additional pockets to retain the filler strip.
[0077] Again, the joint shown in FIG. 8 is the same as the joint in
FIG. 7, except for the addition of the attachment clip 30.
[0078] The joints are shaped to provide ventilation, pressure
equalization chamber buffer(s), internal gutter systems, and
thermal movement. The ventilation's function is to allow for
permeability through impermeable cladding material. This second
(and third, etc) pressure equalization chambers are designed to
prevent water penetration for the extreme cases of kinetic energy
due to a torrential rain storm or its equivalent. In addition,
under extreme wind conditions with wider frequency range, the
second, third, etc., chambers act as secondary buffers for
effective pressure equalization. Weeps located at the bottom of the
wall panel allow for escape from the wall cavity. FIG. 1 shows a
weep 150 on the lower mounting flange 36 of the wall panel unit
22a.
[0079] One embodiment of the single chamber system includes at
least one single chamber vertical joint (shown in FIG. 3), at least
one single chamber horizontal joint (shown in FIG. 4), a means for
attachment for each horizontal joint, and a wall securing device
for each horizontal joint. This system, in conjunction with wall
panels used in the art, allows wall panels to be constructed on the
outside of architectural structures.
[0080] The wall panels used in the art include homogenous and
composite wall panels. These are not limited to any substance,
whether solid or composite, and include plastic, aluminum, zinc,
platinum, titanium, copper, steel, and any other metal or material
that can be used to make either homogenous or composite wall
paneling.
EXAMPLES
[0081] Referring again to FIGS. 2 and 3, the features in this
exemplary embodiment of the horizontal and vertical joints work to
prevent water from penetrating into the architectural wall. This is
proven by the tests represented in the examples below.
[0082] Air infiltration, water penetration, and structural
performance tests of the system installed in a laboratory test
chamber were performed. Wall Assembly A was tested on Apr. 8, 2005;
Wall Assembly B was tested for water penetration in accordance with
ASTM: E 331 on Apr. 22, 2005, and for water penetration in
accordance with ASTM: E 331 but modified to monitor air flow as
openings were cut in the back-up wall on May 6 and Jun. 7, 2005.
The following comments describe the test procedures and results for
each wall assembly.
DESCRIPTIONS OF WALL ASSEMBLIES
[0083] WALL ASSEMBLY A--APR. 8, 2005: water penetration air
infiltration and structural tests were performed on Wall Assembly
A.
[0084] TEST SPECIMEN--DESCRIPTION
[0085] The following wall assembly was mounted in a laboratory test
chamber:
[0086] Dimension of Wall: 10 feet high by 10 feet wide
[0087] Framing: 2''.times.6'' steel stud and stud track,
14-gauge
[0088] Sheathing: 5/8'' thick Dens-Glass
[0089] Air Barrier Membrane: Carlisle CCW-705 sheet membrane
waterproofing system was installed over the Dens-Glass sheathing.
An 18-gauge galvanized steel X deep hat bar was installed over the
insulation. Lymo aluminum composite panels were attached to the hat
bar with a continuous piece of extruded aluminum. Each panel
contained two weep holes. Horizontal flashing was installed over
the top of the system.
[0090] WALL ASSEMBLY B--APR. 22, MAY 6, AND JUN. 7, 2005: water
penetration and air infiltration tests were performed on Wall
Assembly B.
[0091] TEST SPECIMEN--DESCRIPTION
[0092] The following wall assembly was mounted in a laboratory test
chamber:
[0093] Dimension of Wall: 10 feet high by 10 feet wide
[0094] Framing: 2''.times.6'' steel stud and stud track,
14-gauge
[0095] Sheathing: 3/8'' thick plexiglass
[0096] The joints between abutting sheets of plexiglass were
back-sealed against the steel stud framing with Dow silicone
sealant. At perimeter joints, three to four inch wide strips of
Carlisle CCW-705 sheet waterproofing membrane were installed.
[0097] Over all perimeter joints between the perimeter of the
plexiglass and the chamber walls, at vertical joints between the
plexiglass sheets, and horizontally over the surface of the
plexiglass where fasteners from the plexiglass to the studs were
placed and where the 18-gauge galvanized steel 1/2'' deep bars were
installed.
[0098] Panel System: Two metal panel systems were installed. The
directions of "right" and "left" are from the interior view:
[0099] System 1 (Right Side): Standard dry seam metal panel system
(prior art).
[0100] System 2 (Left Side): Lymo Dry Seam 3000 panel system with
double-spline system (double compartment or chamber system
embodiment of present invention)
[0101] TEST PROCEDURES
[0102] A. Air infiltration testing was conducted in accordance with
applicable provisions of ASTM Designation: E 283, "Standard Test
Method for Measurement of Air Leakage Through Exterior Windows,
Curtain Walls, and Doors Under Specified Pressure Differences
Across the Specimen."
[0103] B. Water penetration testing was conducted in accordance
with applicable provisions of ASTM Designation: E 331, "Standard
Test Method for Determination of Water Penetration of Exterior
Windows, Curtain Walls, and Doors by Uniform Static Air Pressure
Difference." This test method was modified by making openings in
the back-up wall and recording the pressure change and air flow
from the chamber while the volume of air being removed from the
chamber was maintained at a constant rate. The modifications were
used during water testing of Wall Assembly B.
[0104] TEST RESULTS
[0105] WALL ASSEMBLY A--APR. 8, 2005
[0106] 1. AIR INFILTRATION@1.57 PSF
[0107] Measured Air Leakage: 0.4 cfm
[0108] Calculated Air Infiltration: 0.004 cfm per square foot
[0109] The allowable increase is 0.004 cubic feet per square foot.
The assembly met the requirement for air infiltration of an air
barrier in the Massachusetts Energy Code.
[0110] 2. WATER PENETRATION
[0111] Water was applied to the `exterior` of the panel system at
the standard rate of 5.0 gallons per hour per square foot while a
negative chamber pressure of 6.24 psf was maintained on the
interior of the wall assembly.
[0112] Test 1 @6.24 psf: No leakage was observed on the `interior`
of the chamber or on the surrounding construction during or
following the 15-minute test period.
[0113] Test 2 @15 psf: No leakage was observed on the `interior` of
the chamber or on the surrounding construction during or following
the 15-minute test period.
[0114] WALL ASSEMBLY B--APR. 22, MAY 6, AND JUN. 7, 2005
[0115] Water was applied to the exterior of the panel system at the
standard rate of 5.0 gallons per hour. The following observations
were made during the tests both before and after holes were made in
the sheathing of the back-up wall, with air flow and pressure
readings taken as part of the observations. The directions of
"right" and "left" are from the interior view.
[0116] Test 1 A 0 psf differential pressure was applied to the test
chamber. Water was observed running down in the wall cavity behind
the standard dry seam metal panel system (right side). No water was
observed in the wall cavity behind the Lymo Dry Seam 3000 Panel
System (left side).
[0117] Test 2 A 15 psf differential pressure was applied to the
test chamber behind the wall system. Water was observed running
down in the wall cavity behind the standard dry seam metal panel
system (right side). No water was observed in the wall cavity
behind the Lymo Dry Seam 3000 Panel System (left side). The air
flow from the test chamber recorded during this test was 97
cfm.
[0118] Test 3 A 1/4'' diameter hole was drilled through the
sheathing on the back-up wall as the vacuum motor and valve
controlling the rate of air extraction from the test chamber were
not changed from the settings for the test chamber differential
pressure of 15 psf. The pressure reading was 14.35 psf. The air
flow reading was 86 cfm.
[0119] Water was observed running down in the wall cavity behind
the standard dry seam metal panel system (right side). No water was
observed in the wall cavity behind the Lymo Dry Seam 3000 Panel
System (left side).
[0120] Test 4 A second 1/4'' diameter hole was drilled through the
sheathing on the back-up wall as the vacuum motor and valve
controlling the rate of air extraction from the test chamber were
not changed from the settings for the test chamber differential
pressure of 15 psf. The pressure reading was 13.31 psf. The air
flow reading was 91 cfm.
[0121] Water was observed running down in the wall cavity behind
the standard dry seam metal panel system (right side). No water was
observed in the wall cavity behind the Lymo Dry Seam 3000 Panel
System (left side).
[0122] Test 5 A third 1/4'' diameter hole was drilled through the
sheathing on the back-up wall as the vacuum motor and valve
controlling the rate of air extraction from the test chamber were
not changed from the settings for the test chamber differential
pressure of 15 psf. The pressure reading was 12.79 psf. The air
flow reading was 90.6 cfm.
[0123] Water was observed running down in the wall cavity behind
the standard dry seam metal panel system (right side). No water was
observed in the wall cavity behind the Lymo Dry Seam 3000 Panel
System (left side).
[0124] Test 6 A 12''.times.12'' hole was cut through the sheathing
on the back-up wall as the vacuum motor and valve controlling the
rate of air extraction from the test chamber were not changed from
the settings for the test chamber differential pressure of 15 psf.
The pressure reading was 0.16 psf. The air flow reading was 81.3
cfm.
[0125] Water was observed running down in the wall cavity behind
the standard dry seam metal panel system (right side). No water was
observed in the wall cavity behind the Lymo Dry Seam 3000 Panel
System (left side).
COMMENTS AND CONCLUSION
[0126] Water was observed in the wall cavity behind a standard dry
seam metal wall panel system prior to allowing the pressure drop to
occur in the wall cavity. The Lymo 3000 double dry seam panel
system was not observed to leak into the wall cavity prior to
allowing the pressure drop to occur in the wall cavity.
ADDITIONAL TESTING
[0127] Additional testing was preformed on Feb. 27 and 28, 2007.
The testing was performed in accordance with AAMA 508-05, Voluntary
Test Method and Specification for Pressure Equalized Rain Screen
Wall Cladding Systems. The testing included air infiltration;
cyclic static air pressure differential; static pressure water
resistance; and dynamic pressure water resistance.
[0128] The wall utilized 0.160'' thick aluminum composite cladding
panels on the exterior. A 61/4'' by 61/4'' aluminum flashing was
installed over the 2.times.12 at the sill of the mock-up. An
aluminum Z-channel was installed over the flashing and the top
edge, and was sealed with Carlisle EZ Flash. The base of the
flashing and Z-channel were secured to the 2.times.12 with a
continuous aluminum angle, secured with 1.times.1'' screws spaced
12'' on center. Panels were attached to the test wall and the sill
with a continuous extruded aluminum channel clip which was fastened
to the aluminum angle with #12.times.1'' screws spaced 16'' on
center. The head of the system utilized a continuous 15/8'' by 3''
aluminum angle secured to the 2.times.12 with #12.times.1'' screws
spaced 12'' on center. The panel was secured at the head with
31/4'' long aluminum clips spaced 16'' on center which were
fastened to the aluminum angle sealed with butyl. The horizontal
joint was comprised of a 3'' wide continuous extruded aluminum clip
secured to the panels by a subgirt and a #12.times.1'' screw. An
aluminum composite material (ACM) filler strip 28 was installed
inside the aluminum perimeter clip 26. The subgirt was fastened to
the steel studs with #14.times.31/2'' screws. The vertical joint
was comprised of a 3'' wide continuous extruded aluminum clip which
was secured to the panels with pop rivets. An ACM filler strip 28
was installed inside the aluminum perimeter clip.
[0129] Test Set-up:
[0130] An 8'0'' wide by 8'0'' high standard wall was constructed
with 14 gauge steel studs 16'' on center inside a 2.times.12 wood
buck. The stud wall was covered by a 1/4'' thick sheet of clear
acrylic sealed and fastened to the exterior of the wall to simulate
an air/water barrier. The Pressure Equalized Rain Screen Wall
Cladding (PRWC) system was then installed onto the acrylic in a
manner consistent with normal construction procedures for the
system. The acrylic was calibrated to a pre-determined air leakage
rate by drilling 1/8'' diameter holes in the backside of the
acrylic, in a uniform pattern, making sure to create an even
pressure drop and leakage rate across the wall and in each
quadrant.
[0131] The Air Infiltration test was pursuant to ASTM E 283-04,
Standard Test Method for Determining the Rate of Air Leakage
Through Exterior Windows, Curtain Walls, and Doors Under Specified
Pressure Differences Across the Specimen. Testing was conducted at
1.57 psf positive static air pressure difference.
[0132] The standard requires infiltration of between 0.418
cfm/ft.sup.2 and 0.511 cfm/ft.sup.2 for 1.57 psf (25 mph). The
result of the testing was 0.464 cfm/ft.sup.2.
[0133] The Cyclic Static Air Pressure Differential test was
pursuant to ASTM E 1233-00, Standard Test Method for Structural
Performance of Exterior Windows, Curtain Walls, and Doors by Cyclic
Static Air Pressure Differential. Testing was conducted at 25 psf
in 100 three-second cycles. The standard allows 0.08 seconds. The
results were less than 0.08 seconds so the test was passed.
[0134] The Static Pressure Water Resistance test was pursuant to
ASTM E 331-00, Standard Test Method for Water Penetration of
Exterior Windows, Curtain Walls, and Doors by Uniform Static Air
Pressure Difference. Testing was conducted at 15.0 psf positive
static air pressure difference for a 15 minute duration. Water was
applied to the mock-up at a minimum rate of 5 gal/ft.sup.2/hr. The
standard allows up to 0.64 ounces of water. Zero ounces penetrated
so the test was passed. Cavity pressure readings were taken in the
top left and bottom right (interior view) quadrants.
[0135] The standard, like the static standard, allows up to 0.64
ounces of water to penetrate. Zero ounces penetrated so the test
was passed. In the tests, water entered through the weeps and
filled the gutters but did not overflow. Water came down the second
right most vertical member at bottom. Furthermore, the test was
conducted at a higher water penetration pressure than required.
[0136] While the principles of the invention have been described
herein, it is to be understood by those skilled in the art that
this description is made only by way of example and not as a
limitation as to the scope of the invention. Other embodiments are
contemplated within the scope of the present invention in addition
to the exemplary embodiments shown and described herein.
Modifications and substitutions by one of ordinary skill in the art
are considered to be within the scope of the present invention,
which is not to be limited except by the following claims.
* * * * *