U.S. patent application number 12/507639 was filed with the patent office on 2010-07-29 for method for installing wall panels to the exterior wall of a building.
Invention is credited to Philip A. MacDonald, Robert B. MacDonald.
Application Number | 20100186343 12/507639 |
Document ID | / |
Family ID | 42353003 |
Filed Date | 2010-07-29 |
United States Patent
Application |
20100186343 |
Kind Code |
A1 |
MacDonald; Robert B. ; et
al. |
July 29, 2010 |
Method for Installing Wall Panels to the Exterior Wall of a
Building
Abstract
A method for installing wall panels to an exterior building wall
is provided. The method applies the rainscreen principle.
Interlocking components are used to attach aluminum or other wall
panels to an exterior wall. In one aspect, the method includes
fastening a bracket assembly to the exterior building wall,
fastening an attachment clip to the bracket assembly, providing a
panel perimeter strip, providing a wall panel, fastening the wall
panel to the panel perimeter strip along one side surface of the
wall panel, providing a through-opening through the wall panel
thereby permitting fluid communication from an atmosphere into the
hollow interior portion of the wall panel, and sliding an infill
strip into a slot of the panel perimeter strip between the
attachment clip and the through opening so as to cover a fastener
of the bracket assembly; The system is held together
non-adhesively.
Inventors: |
MacDonald; Robert B.;
(London, CA) ; MacDonald; Philip A.; (London,
CA) |
Correspondence
Address: |
BAKER, DONELSON, BEARMAN, CALDWELL & BERKOWITZ, PC
265 Brookview Centre Way, Suite 200
KNOXVILLE
TN
37919
US
|
Family ID: |
42353003 |
Appl. No.: |
12/507639 |
Filed: |
July 22, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11273303 |
Nov 14, 2005 |
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12507639 |
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Current U.S.
Class: |
52/747.1 |
Current CPC
Class: |
E04F 13/12 20130101;
E04F 13/0889 20130101; E04F 13/0826 20130101 |
Class at
Publication: |
52/747.1 |
International
Class: |
E04B 2/82 20060101
E04B002/82; E04B 1/38 20060101 E04B001/38 |
Claims
1. A method for installing a wall panel to an exterior building
wall, the wall panel having an exterior flat surface and at least
two side surfaces bent inwardly at an angle to the exterior flat
surface and defining a hollow interior portion, and the method
comprising: operatively connecting an attachment clip to a wall
surface of the exterior building wall, the attachment clip having a
central fastening surface and at least two opposing wing members
extending outwardly from the central fastening surface; providing a
first panel perimeter strip comprising: a generally C-shaped 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 C-shaped member that extends beyond the
side surface of the wall panel and provides a slot adapted to
engage and interlock a first of the at least two wing members of
the attachment clip, thus connecting the wall panel to the
attachment clip and thereby to the wall; fastening the wall panel
to the first panel perimeter strip along one side surface of the
wall panel; providing a through-opening through the wall panel,
thereby permitting fluid communication from an atmosphere into the
hollow interior portion of the wall panel and so as to permit
ingress and egress of air and moisture to provide a
pressure-balanced and moisture-drained interior environment for the
wall panel; and sliding an infill strip into the slot of the first
panel perimeter strip between the attachment clip and the through
opening; wherein the system is held together non-adhesively.
2. The method of claim 1, further comprising fastening a bracket
assembly to the exterior building wall; and wherein: the step of
operatively connecting the attachment clip to the wall surface of
the exterior building wall comprises fastening the attachment clip
to the bracket assembly by at least one fastener; and the infill
strip covers the fastener of the bracket assembly.
3. The method of claim 2, wherein the two wing members of the
attachment clip are each adapted to engage a receiving member of a
panel perimeter strip.
4. The method of claim 3, wherein: fastening the wall panel to the
first panel perimeter strip comprises running at least one rivet
through the first panel perimeter strip and through the one side
surface of the wall panel; and the through-opening through the wall
panel defines the at least one rivet such that the interior portion
of the wall panel is ventilated at least partially through the at
least one rivet.
5. The method of claim 4, wherein the infill strip is fabricated
from a substantially rigid material comprising a metal material, a
polycarbonate material, polyethylene, or combinations thereof.
6. The method of claim 2, wherein the first 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.
7. The method of claim 1, wherein the wall panel comprises an
aluminum composite material.
8. The method of claim 1, wherein the wall panel comprises an
aluminum composite material which is routed and bent generally
perpendicularly to form the exterior and side surfaces.
9. The method of claim 1, wherein the first fastener comprises a
threaded fastener.
10. The method of claim 1, wherein the panel perimeter strip is
pre-assembled to the wall panel before being fastened to the first
bracket assembly.
11. The method of claim 2, further comprising: providing a second
panel perimeter strip in accordance with the first panel perimeter
strip; attaching a second panel perimeter strip to a second of the
at least two opposing wing members of the attachment clip;
fastening a second wall panel to the second panel perimeter strip
along one side surface of the second wall panel such that the side
surface of the second wall panel faces the side surface of the
first wall panel; and providing a through-opening through the
second wall panel, thereby permitting fluid communication from the
atmosphere into the hollow interior portion of the second wall
panel.
12. The method of claim 11, wherein the infill strip is engaged
with the slot of the first panel perimeter strip prior to
installing the second wall panel.
13. The method of claim 11, wherein: the first panel perimeter
strip and the second panel perimeter strip are adjacent one
another; and the infill strip is introduced to the slots of the
first and second adjacent panel perimeter strips after two adjacent
wall panels have been installed.
14. The method of claim 11, further comprising: applying an
isolation tape between the attachment clip and the bracket
assembly.
15. The method of claim 2, wherein the bracket assembly comprises
steel.
16. The method of claim 1, wherein the infill strip comprises a
strip of aluminum composite material.
17. The method of claim 11, further comprising: installing a panel
stiffener component inside the hollow interior portion of the first
and second wall panels to reinforce the exterior surfaces of the
wall panels and preventing deforming or popping of the wall panels.
Description
STATEMENT OF RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. patent
application Ser. No. 11/273,303 which was filed on Nov. 14, 2005.
That application is titled "Dry Joint Aluminum Wall Panel
Attachment System," and was published as U.S. Patent Publ. No.
2007/0119105. The application is incorporated herein in its
entirety by reference.
BACKGROUND OF THE INVENTION
[0002] This section is intended to introduce various aspects of the
art, which may be associated with exemplary embodiments of the
present disclosure. This discussion is believed to assist in
providing a framework to facilitate a better understanding of
particular aspects of the present disclosure. The Background
section should be read in this light, and not necessarily as
admissions of prior art.
[0003] 1. Field of the Invention
[0004] The present disclosure relates to wall panel attachment
systems. More particularly, the present disclosure pertains to
methods of attaching wall panels to exterior wall surfaces.
[0005] 2. Discussion of Technology
[0006] There are various problems with known aluminum wall panel
attachment systems. Conventionally, such systems have relied upon
adhesive or caulk to "seal" the aluminum panel from the elements.
However, under exposure to heat and cold and moisture, the adhesive
or caulk breaks down. This, in turn, compromises the stability of
the system and creates an undesirable appearance. Even when such a
seal is functional, there may be 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.
[0007] More recently systems have been developed according to the
"rainscreen principle." This means that the wall cavity is vented,
resulting in a temperature and pressure equalized system with
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 costs and specialty
materials. A need exists for a method of installing wall panels
using exterior wall panel attachment systems and which permit the
ingress and egress of moisture behind the panels.
SUMMARY OF THE INVENTION
[0008] A method for installing wall panels to an exterior building
wall is provided. The wall panel has an exterior flat surface and
at least two side surfaces bent inwardly at an angle to the
exterior flat surface and defining a hollow interior portion. The
wall panel preferably comprises an aluminum composite material. In
one arrangement, the wall panel comprises an aluminum composite
material which is routed and bent generally perpendicularly to form
the exterior and side surfaces.
[0009] In one aspect, the method includes fastening a bracket
assembly to the exterior building wall. The bracket assembly may
define two back-to-back L-angle brackets fastened to each other to
form a generally Z-shaped assembly. A first end of the L-angle
bracket is for attachment to the wall, and a second end is for
fastening to the attachment clip. The bracket assembly may comprise
steel.
[0010] The method also includes fastening an attachment clip to the
bracket assembly by at least one fastener. The attachment clip has
a central fastening surface fastened to the bracket assembly, and
at least two opposing wing members extending outwardly from the
central fastening surface. Preferably, the two wing members of the
attachment clip are each adapted to engage a panel perimeter
strip.
[0011] In one aspect, a bracket assembly is not used and the
attachment clip is not connected to a bracket assembly. Instead,
the bracket assembly connects to additional framing or to shims
that are part of a wall surface.
[0012] The method also includes providing a first panel perimeter
strip. The first panel perimeter strip has a generally C-shaped
member sitting inside a corner of the wall panel. The C-shaped
member extends along an inside portion of the side surface. The
first panel perimeter strip also has a receiving member. The
receiving member is integrally attached to the C-shaped member and
extends beyond the side surface of the wall panel. The receiving
member provides a slot adapted to engage and interlock one of the
wing members of the attachment clip. In this way, the wall panel is
connected to the attachment clip and thereby to the wall.
[0013] The method also includes fastening the wall panel to the
first panel perimeter strip along one side surface of the wall
panel. A through-opening is provided through the wall panel,
thereby permitting fluid communication from an atmosphere into the
hollow interior portion of the wall panel and so as to permit
ingress and egress of air and moisture to provide a
pressure-balanced and moisture-drained interior environment for the
wall panel. The method then includes sliding an infill strip into
the slot of the first panel perimeter strip. The infill strip
resides between the attachment clip and the through opening so as
to cover the fastener of the bracket assembly. The infill strip is
fabricated from a substantially rigid material comprising a metal
material, a polycarbonate material, polyethylene, or combinations
thereof. Preferably, an aluminum composite material is used.
[0014] In one embodiment of the method, fastening the wall panel to
the first panel perimeter strip comprises running at least one
rivet through the first panel perimeter strip and through the one
side surface of the wall panel. The through-opening through the
wall panel defines the at least one rivet such that the interior
portion of the wall panel is ventilated at least partially through
the rivets. Thus, the rivets contribute to the ventilation of the
panel.
[0015] The method is designed to be repeated so as to place a
plurality of wall panels in side-by-side array. Thus, the method
may further comprise: [0016] providing a second panel perimeter
strip in accordance with the first panel perimeter strip; [0017]
attaching a second panel perimeter strip to a second of the at
least two opposing wing members of the attachment clip; [0018]
fastening a second wall panel to the second panel perimeter strip
along one side surface of the second wall panel such that the side
surface of the second wall panel faces the side surface of the
first wall panel; and [0019] providing a through-opening through
the second wall panel, thereby permitting fluid communication from
the atmosphere into the hollow interior portion of the second wall
panel.
[0020] Additional wall panels may be attached to the exterior wall
using additional bracket assemblies, attachment clips and panel
perimeter strips.
[0021] The infill strip may be engaged with the slot of the first
panel perimeter strip prior to installing the second wall panel.
Alternatively, the infill strip may be introduced to the slots of
the first and second adjacent panel perimeter strips after two
adjacent wall panels have been installed.
[0022] The method may also comprise installing a panel stiffener
component. The panel stiffener component is positioned inside the
hollow interior portion of the first and second wall panels to
reinforce the exterior surfaces of the wall panels and to prevent
deforming or popping of the wall panels. In any instance, the wall
panel array is held together non-adhesively.
BRIEF DESCRIPTION OF THE FIGURES
[0023] 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.
[0024] FIG. 1 shows a simplified cut-through view of the dry joint
aluminum wall panel attachment system, according to the preferred
embodiment.
[0025] FIG. 2 shows a panel perimeter strip used in the attachment
system.
[0026] FIG. 3 shows an attachment clip used in the attachment
system.
[0027] FIG. 4 shows a cut-through view of a panel stiffener
optionally used in the attachment system.
[0028] FIG. 5 shows a cut-through view of the aluminum composite
material (ACM) used in the panels.
[0029] FIGS. 6, 7, 8 show progressive steps in the formation of an
ACM panel for use in the present system.
[0030] FIG. 9 shows a cut-through view of an infill strip used in
the attachment system.
[0031] FIG. 10 shows a detailed view of the preferred placement of
the infill strip in the attachment system.
[0032] FIG. 11 shows a simplified elevational view of the
sub-framing used before mounting the ACM panels in the present
system.
[0033] FIG. 12 shows a detailed view of the complete attachment
system with sub-framing.
[0034] FIGS. 13, 14 and 15 show progressive steps in the
installation of panels in the present system (first method).
[0035] FIG. 16 shows a view of the installation of lengths of
infill strip in the present system (second method).
[0036] FIG. 17 shows a view of a finished wall paneled
exterior.
[0037] FIG. 18 shows a cut-through view of an alternative panel
perimeter strip.
[0038] FIGS. 19 and 20 show cut-through views of two versions of an
alternative panel stiffener.
DETAILED DESCRIPTION
[0039] The present panel attachment system 10 uses an extruded
aluminum attachment system for fastening fabricated panels to all
building surfaces 52. The system's strength is further enhanced by
the use of an extruded perimeter frame design.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] 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.
[0045] 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 and 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.
[0046] 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.
[0047] 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.
[0048] 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
assembly (FIG. 8). A standard panel rivet for this application is
3/16'' diameter.
[0049] there are various methods to accomplish the routing and
cutting process:
[0050] Method 1 [0051] 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 labor-intensive method of fabrication due to the lengthy time
for setup and layout of each different panel.
[0052] Method 2 [0053] 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.
[0054] Method 3 [0055] 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.
[0056] 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 48 for the attachment clip (FIG.
10).
[0057] 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.
[0058] 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 from panel to panel.
[0059] 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:
[0060] 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).
[0061] 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).
[0062] 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.
[0063] 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.
* * * * *