U.S. patent application number 12/042043 was filed with the patent office on 2010-08-19 for method and apparatus for mounting a wall system.
Invention is credited to Craig D. Carson.
Application Number | 20100205883 12/042043 |
Document ID | / |
Family ID | 41050563 |
Filed Date | 2010-08-19 |
United States Patent
Application |
20100205883 |
Kind Code |
A1 |
Carson; Craig D. |
August 19, 2010 |
METHOD AND APPARATUS FOR MOUNTING A WALL SYSTEM
Abstract
Disclosed is a wall system employing one or more stackable
connectors that are capable of engaging one with another
independent of fasteners and being mountable to a respective wall
panel.
Inventors: |
Carson; Craig D.;
(Elizabeth, CO) |
Correspondence
Address: |
A LAW FIRM, P.C.
8753 YATES DRIVE, SUITE 215
WESTMINSTER
CO
80031
US
|
Family ID: |
41050563 |
Appl. No.: |
12/042043 |
Filed: |
March 4, 2008 |
Current U.S.
Class: |
52/281 ; 403/363;
52/483.1; 52/745.1 |
Current CPC
Class: |
Y10T 403/7043 20150115;
E04B 1/6179 20130101; E04F 13/12 20130101; E04B 1/08 20130101; E04F
13/081 20130101 |
Class at
Publication: |
52/281 ; 403/363;
52/483.1; 52/745.1 |
International
Class: |
E04B 2/88 20060101
E04B002/88; E04B 1/38 20060101 E04B001/38; E04G 21/14 20060101
E04G021/14; E04F 13/21 20060101 E04F013/21 |
Claims
1. A connector for use with a metal wall panel system, said
connector comprising: a pair of rigid angular bodies each having at
least one leg element and one receiving member; said pair of bodies
capable of being mated one with the other when a leg element of
said first body interlocks a corresponding receiving member of said
second body; and said first body capable of overlaying a portion of
a horizontal track member of a metal stud frame.
2. The connector of claim 1, wherein said leg element further
comprises a pleated edge.
3. A wall panel system comprising: a first connector mountable to a
head portion of a respective wall panel; wherein said wall panel is
mounted to a base; said first connector comprising at least one
receiving member to receive a leg of a second connector; said
second connector mounted to a sill portion of a respective wall
panel; and wherein a horizontal joint is formed when said receiving
member of said first connector and said leg of said second
connector are engaged one with another.
4. The system of claim 3, wherein said base further comprises to a
floor to accommodate one or more structural loads.
5. The system of claim 3, wherein said base further comprises an
overlying floor.
6. A connection system for panelized wall cladding, said system
comprising: a first connector mountable to a horizontal track
member of a frame, said first connector capable of being fastened
to a vertical stud of said frame; said first connector further
comprising at least one receiving member to receive a leg member of
an adjacent connector; said adjacent connector further comprising a
receiving member to receive a leg member of said first connector;
and wherein a horizontal joint is formed contiguous with said
horizontal track member when said first connector and said adjacent
connector are engaged one with another.
7. The system of claim 6, wherein said first or said adjacent
connector comprises a metal plate bent to a desired profile.
8. The system of claim 6, wherein said horizontal joint is capable
of transferring one or more building loads.
9. The system of claim 6, wherein said first or said adjacent
connector is capable of being affixed to a portion of a respective
wall panel.
10. The system of claim 6 further comprising one or more exterior
finish products capable of being preinstalled off-site or applied
in situ.
11. The system of claim 10, wherein said one or more exterior
finish products comprise metal, stucco, tile, and/or brick.
12. The system of claim 6 further comprising one or more air
seals.
13. The system of claim 6 further comprising one or more weeped
drainage systems.
14. A method of constructing a metal wall panel system, said method
comprising: providing a first connector capable of being mounted to
a portion of a horizontal track of a building frame, said first
connector fastenable to a vertical stud of said building frame,
said first connector further being fastenable to a head portion of
a wall panel; positioning a receiving of a second connector to
receive a leg member of said first connector, said second connector
fastenable to a sill portion of a wall panel; and mating said first
and second connectors one to another independent of fasteners.
15. The method of claim 14, wherein said mating step further
comprises forming a horizontal joint along said portion of said
horizontal track, said horizontal joint capable of transferring one
or more building loads.
16. The method of claim 14 further comprising the step of mounting
a series of first and second connectors along a length of said a
horizontal track member, thereby facilitating the mounting of a
series of respective wall panels.
17. The method of claim 14 further comprising the step of anchoring
a first level wall panel to a first floor.
Description
FIELD OF ART
[0001] The disclosed device relates generally to a panelized metal
wall system for exterior wall cladding in the building industry,
and more specifically to a metal stud wall system employing one or
more stackable connectors that are capable of engaging one with
another independent of fasteners and being mountable to a
respective wall panel.
BACKGROUND
[0002] It is well known in the building industry that the term
"cladding" is used to refer to a wide variety of natural,
synthetic, or man-made building envelope materials and components.
Panelized metal wall systems are but one form of cladding suitable
for installation as an exterior side of a building enclosure. Other
types of cladding can include cast in place concrete, pre-cast
concrete, masonry, etc. In selecting the types of metal panels that
meet design criteria for a particular building envelope, a designer
will typically establish panel performance criteria related (but
not limited) to wind loading, seismic considerations, deflection,
thermal movement, air infiltration, moisture management, panel
flatness, panel tolerance, performance testing, fire resistance,
sound transmission, insulation, and/or maintainability.
[0003] Each wall system is typically adapted to its intended
building use. Thus, a metal wall building envelope can comprise
flat plate metal panels, lap seam metal panels, composite metal
panels, and/or metal-faced composite panels. In addition, the type
of metal typically can include aluminum, steel, stainless steel, or
copper. Steel panel systems, however, may necessitate a protective
coating for corrosion resistance. Metal panels are typically
screwed or bolted directly on a structural frame often consisting
of metal studs. Ideally, the design of the metal stud framing
should be integrated with the panel design and the relevant
fastening system.
[0004] Often a metal panel will be selected almost solely for the
overall look it provides with little consideration for the method
of panel engagement. Decisions based on aesthetics alone can often
overlook issues related to one or more of the above-mentioned
design criteria, and vice versa. For example, systems that employ a
tongue and groove method of engagement can result in a seam
vulnerable to water infiltration. Lap seam metal panels, on the
other hand, can remedy the water infiltration problem but the use
of these panels can result in exposed fasteners, which then require
maintenance to prevent leaks at the fastener locations. Since lap
seam metal panels do not readily accommodate the issue of thermal
movement, panel lengths may become limited. Recent developments in
the industry have resulted in metal wall panels that can offer the
appearance of a lap seam panel but use interlocking cleats to
secure the panel to the structure without the use of exposed
fasteners, thereby providing improved appearance, weather
tightness, and management of thermal movement. In short,
conventional panels can provide a system having a plurality of
panels that interlock with one another in an end-to end manner. In
addition, with the conventional art, metal panels appear to be
erected directly on the exterior of the metal stud framing and add
little or no stress benefit. Not only can the disclosed device
provide for a metal wall panel system that can accommodate
aesthetics, it can facilitate a secure and beneficial method of
panel engagement.
[0005] The building envelope has been a target of innovation.
Developments in the wall systems of the envelope are generally
attributed to: 1) cost reduction for a competitive market, 2)
material innovation, 3) enhanced performance, and 4) aesthetics.
The Applicant has developed a device that enhances the building
envelope industry and can provide a cost-effective and
high-performance method of constructing a metal wall panel system.
Further, the disclosed device can be instrumental in facilitating a
wall system with a high aesthetic level.
[0006] If properly designed and constructed, metal panel systems
can require little maintenance. It is well known in the industry,
however, that the quality and integrity of metal panel systems can
vary by vendor, installer, or other contractor or subcontractor. In
addition, problems associated with fabrication, design, shipping
and handling, or installation can affect the appearance and/or
performance of one or more panels or the wall system itself. The
disclosed device can help to alleviate such problems, thereby
increasing the likelihood that a metal panel system is properly
constructed and/or installed which can result in an increase in
maintainability.
[0007] Not only does the disclosed device provide for ease and
consistency of installation, but if desired, any number of exterior
finish products can be pre-installed off-site (i.e., unitized
system) or applied in situ (i.e., stick system) to optimize a
building envelope project. Examples of exterior finish products can
include but is not limited to metal, stucco, tile, brick, etc.
SUMMARY OF THE DISCLOSURE
[0008] The disclosed device provides a metal wall panel system
comprising one or more metal plates bent to a desired profile and
capable of forming a connection system. The connection system is
capable of forming a horizontal joint that can accommodate building
movements by means of effective load transfer.
[0009] The connectors can mate with each other independent of
fasteners wherein a leg element of a first connector interlocks a
corresponding receiving member or track of a second connector. In
addition, the shape of each of the connectors can be fabricated so
as to be uniform one with another, which can thereby reduce the
overall cost of the system. In operation, the connectors mate by
simply reversing or rearranging one of a pair of connectors and
interlocking the pair.
[0010] These and other advantages of the disclosed device will
appear from the following description and/or appended claims,
reference being made to the accompanying drawings that form a part
of this specification wherein like reference characters designate
corresponding parts in the several views.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1A (prior art) is a perspective view of a typical
corrugated metal wall panel.
[0012] FIG. 1B (prior art) is a front view of the wall panel shown
in FIG. 1A.
[0013] FIG. 2 (prior art) is an elevation view of a metal stud
framing system.
[0014] FIG. 3 (prior art) is a perspective view of a typical
exterior finish product mounted over a metal stud frame.
[0015] FIG. 4 is a perspective view of one embodiment of the
connector disclosed herein.
[0016] FIG. 5 is a side view of the connector of FIG. 4 shown to be
mateable with a second connector.
[0017] FIG. 6 is a side elevation view of a pair of mateable
connectors, each mounted to a portion of a respective stud and
capable of being affixed to a wall panel.
[0018] Before explaining the disclosed embodiments of the disclosed
device in detail, it is to be understood that the device is not
limited in its application to the details of the particular
arrangements shown, since the device is capable of other
embodiments. Also, the terminology used herein is for the purpose
of description and not of limitation.
DESCRIPTION OF THE DISCLOSED FIGURES
[0019] The following description is provided to enable any person
skilled in the art to make and use the disclosed apparatus. Various
modifications, however, will remain readily apparent to those
skilled in the art, since the generic principles of the present
apparatus have been defined herein specifically to provide for
either a unitized or stick system capable of connection with a
metal stud framing system.
[0020] Metal wall panels can be flat or corrugated sheets of metal
manufactured to provide wall cladding for a building exterior and
may be fabricated in a variety of styles and types. Stiffeners and
support structure can be welded or adhered thereto. FIGS. 1A, 1B
depict a conventional corrugated metal wall panel 10 capable of
being mounted on a metal stud frame generally used for
rough-framing in commercial or residential construction and many
other applications.
[0021] As shown in FIG. 2, a metal stud frame typically consists of
two main components: 1) the track and 2) the stud. The dimension of
a room is generally established with horizontal track members 100,
110 anchored respectively to the floor slab 120 and ceiling
joist(s) (not shown) to outline the room. Horizontal members
transfer floor or roof loads to the structural components, i.e.,
beams, girders, columns, etc., of a building. The vertical studs
130 are arranged in the tracks 100, 110, usually spaced about 16"
apart, and fastened at the top and bottom by means of conventional
fasteners, such as wafer screws, framing screws or welding. This
can create a structural framework 140 to support metal wall panels
150 or other finish materials as shown in FIG. 3. Studs 130
constitute structural building components that support vertical
loads and can transfer lateral loads.
[0022] The device disclosed herein may be fabricated in a variety
of designs. FIG. 4 depicts one embodiment of the disclosed device.
In this embodiment, connector 200 comprises a rigid angular body
having a series of parallel and alternating ridges and grooves
designed to overlay a portion of a horizontal track member of a
metal stud frame. A receiving member 230 is shown adjacent leg
members 240, 250. Leg member 240 comprises a pleated or folded edge
245 to accommodate a flashing screw (see FIG. 6 generally).
[0023] In other embodiments, leg member 240 could comprise a
straight edge, an arcuate edge, or any desired combination or
subcombination, depending on the application for which the device
will be used and still fall within the scope and spirit of the
disclosure. Furthermore, other configurations of alternating ridges
and grooves could be suitable. For example, it is contemplated that
the disclosed connector could comprise additional leg members
and/or receiving members if desired and still fall within the scope
and spirit of the disclosure. Although the cold-forming of steel
was implemented in the fabrication of the disclosed device, other
manufacturing processes and materials may be suitable depending on
the particular application.
[0024] Connector 200 comprises edges 210 and 220. In the
configuration shown, connector 200 is mounted at the head of a wall
panel. Thus, edge 210 can interface an inner surface of a metal
wall panel or other finish material. Edge 220 faces an interior of
the building.
[0025] FIG. 5 depicts a second connector notated as connector 300.
Because the disclosed device can be fabricated such that the shape
of each may be uniform with another, a connector 200 can be
positioned as a connector 300 simply by rearranging or reversing
its position. Connector 300 comprises a rigid angular body having a
series of parallel and alternating ridges and grooves. As shown in
FIG. 5, connector 200 may receive a connector 300, wherein the pair
mates to engage one another independent of fasteners. By
rearranging or reversing one of a pair of connectors and mating the
respective units, a user can readily interlock a pair of connectors
for use with a metal wall panel system.
[0026] Referring again to FIG. 4, connector 200 may be mounted to
overlay a portion of a horizontal track member 110 and be fastened
to a vertical stud 130 (see FIG. 2) by any known means. For
example, connector 200 could be welded to the stud if desired,
however, other suitable fastening means could be utilized. It is
contemplated that one or more connectors 200 can be affixed to a
respective length of a horizontal track member to facilitate the
ease of installing a number of exterior wall panels in series. It
is also contemplated that one or more connectors 200 could be used
with a single wall panel if desired.
[0027] As shown in FIG. 5, receiving member 230 may receive a leg
member 340 of an adjacent connector. Correspondingly, receiving
member 330 may receive a leg member 240 of an adjacent connector.
Thus, a horizontal joint can be formed along a portion of a
horizontal track member when a pair of adjacent connectors is
engaged. As stated above, leg members 240, 340 are shown to have a
pleated or folded edge. However, the leg members of the disclosed
device could comprise a straight edge, an arcuate edge, or any
desired combination depending on the application for which the
device will be used. In the configuration shown, edges 210, 320
interface an inner surface of a metal wall panel or other finish
material. Edges 220, 310 are exposed to an interior of the
building. Connector 300 can be mounted at the sill portion of a
wall panel. In cases where a series of connectors 200 are
implemented, one or more corresponding connectors 300 could be
used.
[0028] FIG. 6 depicts a pair of mateable connectors 200, 300 and
capable of being affixed to a respective wall panel 260, 360. Any
number of suitable types of panels, sealant, flashing, insulation,
and fasteners may be utilized in conjunction with the disclosed
device as necessitated by the particular building envelope project
and as would be known to a skilled artisan. For example, an air
seal 400 could be installed in receiving member 330 and adjacent an
end of leg member 240. A wide variety of designs may also be used
to prevent water leakage for metal panel systems including face
sealed barrier systems, weeped drainage systems, and rainscreens.
For example, an end dam 500 could be installed to help seal a wall
panel for use as a gutter from which condensation buildup within
the stud cavity may weep through one or more weep holes (not
shown). Such an installation can act as a secondary or incidental
system of water relief for finishes attached directly to the metal
stud face of the wall panel.
[0029] A first level wall panel can either be anchored to a first
floor (or bulkhead) or hung from an overlying floor. Consecutive
wall panels can be hung from a respective overlying floor to engage
an underlying panel by means of the disclosed device. In addition,
the disclosed device can be used in conjunction with a series of
wall panels hung along the length of a horizontal track member.
[0030] Thus, the disclosed device 1000 provides for a wall system
comprising: a first connector mounted to a head portion of a
respective wall panel, wherein said wall panel is anchored to a
floor to accommodate one or more structural loads; said first
connector comprising at least one receiving member to receive a leg
of a second connector; said second connector mounted to a sill
portion of a respective wall panel; and wherein a horizontal joint
is formed when said receiving member of said first connector and
said leg of said second connector are engaged. Alternately, the
disclosed device 1000 provides for a wall panel system comprising:
a first connector mounted to a head portion of a respective wall
panel, wherein said wall panel is mounted to a base; said first
connector comprising at least one receiving member to receive a leg
of a second connector; said second connector mounted to a sill
portion of a respective wall panel; and wherein a horizontal joint
is formed when said receiving member of said first connector and
said leg of said second connector are engaged.
[0031] The disclosed device also provides for a first connector
mountable to a horizontal track member, said first connector
capable of being fastened to a vertical stud of a metal framing
system; said first connector further comprising at least one
receiving member to receive a leg member of an adjacent connector;
said adjacent connector further comprising a receiving member to
receive a leg member of said first connector; and wherein a
horizontal joint is formed when said first connector and said
adjacent connector are engaged.
[0032] As stated above, metal wall systems can constitute cladding
suitable for installation as an exterior side of a building
enclosure. Thus, metal panel systems are typically considered to be
nonstructural elements that are used to form a curtain wall.
Nonetheless, these nonstructural elements are typically engineered
to support gravity, seismic and wind loading. Not only should loads
from the panels be transmitted to the building's structural frame,
the panels should allow thermal movements and be designed so as not
to restrain the building's structural system as it deforms under
lateral and gravity loads.
[0033] Although the disclosed device may be used in conjunction
with non-structural metal panels, the disclosed system can enhance
both the structural or non-structural components of the building
envelope by its ability to control interstory drift, or the
shifting of floors relative to one another when a building
undergoes wind or earthquake loading. By supporting the horizontal
track members anchored to one or more floor slabs or ceiling joists
and forming a corresponding movable horizontal joint, the disclosed
device can accommodate drifts by flexing or otherwise moving
relative to the drift occurrence. The horizontal joint formed by
the disclosed device helps to transfer a floor or roof load to the
structural component of a building similar to the load transfer by
the horizontal track members. Thus, the disclosed device can be
beneficial in meeting design requirements in seismic zones. The
disclosed device can also be useful in accommodating building
movements or deflection attributed to live loads.
[0034] As stated above, the disclosed device can be utilized in
either a unitized application or a stick built application.
Further, the disclosed device could also be used in conjunction
with non-metal framing systems if applicable.
[0035] Although the disclosed device and method have been described
with reference to disclosed embodiments, numerous modifications and
variations can be made and still the result will come within the
spirit and scope of the disclosure. No limitation with respect to
the specific embodiments disclosed herein is intended or should be
inferred.
* * * * *