U.S. patent application number 13/329409 was filed with the patent office on 2012-04-12 for wall panel systems for rigid wall panels.
Invention is credited to Philip A. Macdonald, Robert B. Macdonald.
Application Number | 20120085042 13/329409 |
Document ID | / |
Family ID | 45924016 |
Filed Date | 2012-04-12 |
United States Patent
Application |
20120085042 |
Kind Code |
A1 |
Macdonald; Robert B. ; et
al. |
April 12, 2012 |
Wall Panel Systems for Rigid Wall Panels
Abstract
Wall panel systems are provided. The systems use interlocking
components to attach photovoltaic (PV), ceramic, or other rigid
wall panels to an exterior wall of a building.
Inventors: |
Macdonald; Robert B.;
(London, CA) ; Macdonald; Philip A.; (London,
CA) |
Family ID: |
45924016 |
Appl. No.: |
13/329409 |
Filed: |
December 19, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12829503 |
Jul 2, 2010 |
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13329409 |
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11273303 |
Nov 14, 2005 |
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12829503 |
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Current U.S.
Class: |
52/173.3 ;
52/235; 52/302.1 |
Current CPC
Class: |
Y02B 10/10 20130101;
F24S 20/69 20180501; F24S 25/636 20180501; E04F 13/0889 20130101;
F24S 25/67 20180501; Y02E 10/44 20130101; H02S 20/23 20141201; F24S
25/40 20180501; Y02E 10/50 20130101; E04F 13/0826 20130101; E04F
13/12 20130101; Y02B 10/20 20130101; Y02E 10/47 20130101 |
Class at
Publication: |
52/173.3 ;
52/235; 52/302.1 |
International
Class: |
E04B 2/88 20060101
E04B002/88; E04B 1/70 20060101 E04B001/70; F24J 2/52 20060101
F24J002/52 |
Claims
1. A wall panel system for attaching multiple wall panels to an
exterior building wall, each wall panel having a dead load, and the
system comprising: a plurality of rigid wall panels; a plurality of
bracket assemblies configured to be fastened to the exterior wall;
a plurality of attachment clips configured to be fastened to
respective bracket assemblies by a fastener and to carry the dead
loads of the respective wall panels, each attachment clip having a
central fastening surface fastened to the bracket assembly and a
pair of integrally formed wing members extending outwardly from the
central fastening surface; a plurality of tile perimeter strips
configured to reside along a rear surface of a respective wall
panel, each tile perimeter strip comprising: a generally C-shaped
member having a planar surface configured to reside along a rear
surface of a respective wall panel, and a receiving member
integrally attached to the C-shaped member and having a slot
adapted to engage and interlock one of the wing members of the
attachment clip, thus operatively connecting a respective wall
panel to the attachment clip and, thereby, to the wall; wherein the
system is configured to allow wall panels to be secured to
respective bracket assemblies in any sequence.
2. The attachment system of claim 1, wherein each panel comprises a
plurality of photovoltaic cells for converting solar energy to
electrical energy.
3. The attachment system of claim 2, wherein each panel further
comprises: a substantially flat exterior surface; and an electrical
cable for delivering electrical current from the plurality of
photovoltaic cells.
4. The attachment system of claim 1, wherein each panel is
fabricated from a ceramic material.
5. The attachment system of claim 4, wherein: each panel further
comprises a substantially flat exterior surface; and each panel is
fabricated from a porcelain material to form a porcelain ceramic
tile.
6. The attachment system of claim 4, further comprising: a
plurality of thin metallic sheets placed along and connected to the
planar surface of the panel perimeter strips, wherein each of the
plurality of ceramic panels is adhesively connected to a
corresponding metallic sheet.
7. The attachment system of claim 1, wherein: each 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 an attachment clip; and the pairs of wing members of the
attachment clips extends outwardly from the central fastening
surface in a substantially symmetrical manner.
8. The attachment system of claim 1, wherein each C-shaped member
further comprises a through-opening to permit the ingress and
egress of air and moisture behind the rigid wall panels to provide
a pressure-balanced and moisture-drained environment.
9. The attachment system of claim 1, further comprising: a
plurality of infill strips non-sealingly disposed within respective
slots of the tile perimeter strips so as to cover the fastener,
each infill strip being fabricated from a substantially rigid
material comprising aluminum, aluminum and polyethylene, polyvinyl
chloride (PVC), or combinations thereof.
10. The attachment system of claim 1, wherein each fastener
comprises a threaded fastener.
11. The attachment system of claim 1, wherein each panel perimeter
strip is pre-adhered to a wall panel before installation to the
building wall.
12. The attachment system of claim 1, further comprising: an
isolation tape applied between each attachment clip and a
corresponding bracket assembly.
13. The attachment system of claim 1, wherein: each attachment clip
comprises aluminum; and each bracket assembly comprises steel.
14. The attachment system of claim 1, wherein each tile perimeter
strip is fabricated at least partially from anodized aluminum.
15. The attachment system of claim 1, further comprising: a panel
stiffener placed between opposing tile perimeter strips along the
rear surface of each wall panel to reinforce each wall panel.
16. The attachment system of claim 1, further comprising: an
adhesive applied to the rear surface of each wall panel and adhered
to each tile perimeter strip along the planar surface, wherein the
adhesive comprises structural silicone adhesive, bonding tape, or
combinations thereof.
17. The attachment system of claim 16, wherein: the adhesive is a
structural silicone adhesive applied to the rear surface of each
wall panel; and the adhesive on each rear surface resides adjacent
a strip of foam tape.
18. A photovoltaic (PV) wall panel system for attaching multiple PV
wall panels to an exterior building wall, each PV wall panel having
a dead load, and the system comprising: a plurality of PV wall
panels, each PV wall panel comprising a plurality of photovoltaic
cells for converting solar energy to electrical energy; a plurality
of bracket assemblies configured to be fastened to the exterior
building wall; a plurality of attachment clips configured to be
fastened to respective bracket assemblies by a fastener and to
carry the dead loads of the respective PV wall panels, each
attachment clip having a central fastening surface fastened to the
bracket assembly and at least one integrally formed wing member,
each wing member extending from the central fastening surface; a
plurality of tile perimeter strips, each tile perimeter strip
comprising: a generally C-shaped member having a planar surface
configured to reside along a rear surface of a respective PV wall
panel, and a receiving member integrally attached to the C-shaped
member having a slot adapted to engage and interlock one of the
wing members of the attachment clip; and an adhesive for connecting
the wall panels to the planar surfaces of the C-shaped members at
least along selected edges; and wherein the system is configured to
allow the PV wall panels to be secured to respective bracket
assemblies in any sequence.
19. The attachment system of claim 18, further comprising: one or
more cable guides attached to each bracket assembly, wherein each
of the cable guides is configured to receive electrical cables
extending from the rear surface of the PV wall panels for
delivering electrical current from the plurality of photovoltaic
cells.
20. The attachment system of claim 18, further comprising: at least
one panel stiffener fixed between the C-shaped members of opposing
tile perimeter strips to provide support for each PV wall panel
along the rear surface.
21. The attachment system of claim 18, wherein the adhesive
comprises structural silicone adhesive, strips of bonding tape, or
combinations thereof.
22. The attachment system of claim 18, wherein: the adhesive is a
structural silicone adhesive applied to the rear surface of each
wall panel; and the adhesive on each rear surface resides adjacent
a strip of foam tape.
23. A hybrid wall panel system for attaching multiple wall panels
to an exterior building wall, each wall panel having a dead load,
and the system comprising: a plurality of bracket assemblies
configured to be fastened to the exterior wall; a plurality of
attachment clips configured to be fastened to respective bracket
assemblies by a fastener and to carry the dead loads of the
respective wall panels, each attachment clip having a central
fastening surface fastened to the bracket assembly and a pair of
integrally formed wing members, each wing member extending from the
central fastening surface; a plurality of solar wall panels, each
solar wall panel having a plurality of photovoltaic cells for
converting solar energy to electrical energy; a plurality of tile
perimeter strips configured to be adhesively connected to a rear
surface of a respective solar wall panel, each tile perimeter strip
comprising: a generally C-shaped member having a planar surface
configured to reside along a rear surface of a respective wall
panel, and a receiving member integrally attached to the C-shaped
member and having a slot adapted to engage and interlock one of the
wing members of the attachment clip, thus operatively connecting a
respective wall panel to the attachment clip and, thereby, to the
wall; an adhesive for connecting the solar wall panels to the
planar surfaces of the C-shaped members at least along selected
edges; a plurality of non-PV wall panels, each non-PV wall panel
having an exterior flat surface and at least two side surfaces bent
generally perpendicularly to the exterior flat surface and defining
a hollow interior portion; a plurality of panel perimeter strips
configured to be fastened to one side surface of a respective
non-PV wall panel, each panel perimeter strip comprising: a
generally C-shaped member configured to extend reside inside of and
reside along an inside portion of a side surface of a respective
wall panel, and a receiving member integrally attached to the
C-shaped member configured to extend beyond the side surface of a
wall panel and having a slot adapted to engage and interlock one of
the wing members of the attachment clip, thus operatively
connecting a respective wall panel to the attachment clip and,
thereby, to the wall; one or more rivets provided along the side
surface of respective non-PV wall panels to connect the side
surface to the receiving member of a respective panel perimeter
strip; wherein: the hybrid system is configured to allow non-PV
wall panels to be secured to respective bracket assemblies in any
sequence; at least one solar wall panel is adjacent to at least one
non-PV wall panel; and the tile perimeter strips and the panel
perimeter strips are dimensioned and configured such that the
exterior surfaces of the solar wall panels and the non-PV wall
panels are substantially flush with one another.
24. The attachment system of claim 23, further comprising: at least
one panel stiffener fixed between the C-shaped members of opposing
tile perimeter strips to provide support for each PV wall panel
along the rear surface.
25. The attachment system of claim 23, wherein the adhesive
comprises structural silicone adhesive, bonding tape, or
combinations thereof.
26. The attachment system of claim 23, wherein: the adhesive is a
structural silicone adhesive applied to the rear surface of each
wall panel; and the adhesive on each rear surface resides adjacent
a strip of foam tape.
27. The attachment system of claim 23, wherein the system is
configured to allow the solar wall panels to be secured to
respective bracket assemblies in any sequence.
Description
STATEMENT OF RELATED APPLICATIONS
[0001] This application is filed as a continuation-in-part patent
application, and claims the benefit of U.S. patent application Ser.
No. 12/829,503, which was filed on 2 Jul. 2010. That application is
entitled "Dry Joint Wall Panel Attachment System," and published as
U.S. Patent Publ. No. 2010/0263314.
[0002] This parent application was a continuation-in-part of U.S.
patent application Ser. No. 11/273,303 which was filed on 14 Nov.
2005 (now abandoned). That application was entitled "Dry Joint
Aluminum Wall Panel Attachment System," and published as U.S.
Patent Publ. No. 2007/0119105.
[0003] These prior applications are incorporated herein in their
entirety by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0004] Not applicable.
THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0005] Not applicable.
BACKGROUND OF THE INVENTION
[0006] 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.
FIELD OF THE INVENTION
[0007] The present disclosure relates to wall panel attachment
systems which include photovoltaic (PV, or solar) panels and
porcelain ceramic tile (PCT) panels. The present disclosure also
pertains to methods of attaching rigid wall panels to exterior wall
surfaces.
DISCUSSION OF TECHNOLOGY
[0008] Attachment systems for exterior walls of buildings are
known. These attachment systems are used for attaching aluminum
wall panels along an exterior surface.
[0009] The known aluminum wall panel attachment systems have
obstacles. Conventionally, these systems rely 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.
[0010] Even when such a seal is functional, there may be
undesirable effects on the aluminum panels. In this respect, the
interior environment can trap heat which affects the individual
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. This, in turn, results in
oxidation of parts and staining or deterioration of exterior wall
surfaces.
[0011] 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. Therefore, a need exists for an improved wall panel
attachment system which permits the ingress and egress of moisture
behind the panels. Further, a need exists for an attachment system
in which the wall panels can be attached to a wall in any
sequence.
[0012] It is also desirable to modify an aluminum wall panel
attachment system for use with other types of panels. For example,
it is desirable for such attachment systems to accommodate
photovoltaic (PV, or solar) panels. Given the increasing prevalence
of solar energy use in commercial buildings, the vertical wall
surfaces present a logical location for the placement of such
panels. While solar panels are manufactured in a wide range of
sizes and shapes, a need exists to incorporate solar panels into an
innovative panel attachment system that permits flush assembly with
non-solar panels and reliable operation of the solar energy
collection system.
[0013] It is further desirable to modify an aluminum wall panel
attachment system to accommodate the use of stiff or non-bendable
panels, such as porcelain or other ceramic panels.
SUMMARY OF THE INVENTION
[0014] Wall panel systems for attaching wall panels to an exterior
building wall are provided herein. In one aspect, the wall panel
system provides a plurality of solar (or PV) panels that are
attached to the building wall side-by-side. In another aspect, the
wall panel system provides solar panels placed adjacent to aluminum
(or other non-solar) wall panels. In yet another aspect, the wall
panel system provides a plurality of ceramic panels that are
attached to the building wall side-by-side.
[0015] First, a wall panel system is provided. The system allows
for the attachment of two or more adjacent rigid wall panels to an
exterior building wall. The rigid wall panels are either PV wall
panels or ceramic wall panels. In one embodiment, the system
includes a plurality of rigid wall panels, a plurality of bracket
assemblies configured to be fastened to the exterior building wall;
and a plurality of attachment clips configured to be fastened to
respective bracket assemblies by a fastener and to carry the dead
loads of the respective rigid wall panels. Preferably, the bracket
assemblies are fabricated from steel for strength.
[0016] Each attachment clip has a central fastening surface
fastened to the bracket assembly. Further, each attachment clip has
a pair of integrally formed wing members. The wing members extend
from a central fastening surface, preferably in a substantially
symmetrical manner.
[0017] The rigid wall panel system also includes a plurality of
tile perimeter strips. Each tile perimeter strip comprises a
generally C-shaped member having a planar surface configured to
extend along a rear surface of a respective wall panel. Each tile
perimeter strip further comprises a receiving member integrally
attached to the C-shaped member and having a slot adapted to engage
and interlock one of the wing members of the attachment clip.
[0018] The rigid wall panels are adhesively connected to respective
planar surfaces of the tile perimeter strips. The adhesive
connection may be through a high-strength bonding tape, a
structural silicone adhesive and sealant, or a combination of both.
It is noted that while the adhesive connection may provide a
substantially water-proof seal along a perimeter of the panel, the
C-shaped member may have a through-opening to permit the ingress of
air behind the rigid wall panels.
[0019] In a preferred embodiment using PV wall panels, the system
further includes one or more cable guides. The cable guides may be
attached to respective bracket assemblies. Each of the cable guides
is configured to receive an electrical cable extending from the
rear surface of the respective PV wall panels.
[0020] In an alternate embodiment, and as noted above, a PV wall
panel may be placed on an exterior building wall adjacent to a
non-PV wall panel, such as an aluminum composite panel. For this
arrangement, an alternate wall panel system is provided that is a
hybrid wall panel system.
[0021] The hybrid wall panel system first includes a plurality of
PV (or other rigid) wall panels. In the case of solar wall panels,
each PV wall panel defines a plurality of photovoltaic cells
configured to convert solar energy into electrical energy. Further,
each PV wall panel comprises an exterior flat surface as noted
above.
[0022] In addition, the hybrid wall panel system includes a non-PV
wall panel. The non-PV wall panel has an exterior flat surface and
at least two side surfaces bent generally perpendicularly to the
exterior flat surface. In this way, a hollow interior portion is
defined inside each non-PV wall panel. Preferably, each non-PV wall
panel comprises an aluminum composite material.
[0023] The hybrid wall panel system may also include a plurality of
bracket assemblies. Each bracket assembly is configured to be
fastened to the exterior wall. In one aspect, each bracket assembly
comprises two back-to-back L-angle brackets fastened to each other
to form a generally Z-shaped assembly. A first end is for
attachment to the wall, and a second end is for fastening to an
attachment clip.
[0024] The wall panel system also has a plurality of attachment
clips. Each clip is preferably fabricated from aluminum, and is
configured to be fastened to a respective bracket assembly by a
fastener. Preferably, each fastener comprises a threaded fastener.
The attachment clips carry the dead loads of the various wall
panels.
[0025] Each attachment clip has a central fastening surface
configured to be fastened to the bracket assembly. Each attachment
clip further has a pair of integrally formed wing members. Each
wing member extends outwardly from the central fastening surface,
preferably in a substantially symmetrical manner. Preferably,
isolation tape is applied between the attachment clips and the
respective bracket assemblies.
[0026] The hybrid wall panel system also includes a plurality of
perimeter strips. Preferably, each perimeter strip is fabricated
from aluminum. Perimeter strips that support the solar or PV wall
panels are referred to as tile perimeter strips; perimeter strips
that support the non-PV wall panels are referred to as panel
perimeter strips.
[0027] Each tile perimeter strip is configured as the tile
perimeter strips described above. In this respect, each tile
perimeter strip is configured to adhesively connect to a rear
surface of a respective PV panel. At the same time, each panel
perimeter strip is configured to be fastened to one side surface of
a respective wall panel.
[0028] Each tile perimeter strip comprises a generally C-shaped
member having a planar surface configured to extend along a rear
surface of a respective PV wall panel. Each tile perimeter strip
further comprises a receiving member integrally attached to the
C-shaped member and having a slot adapted to engage and interlock
one of the wing members of the attachment clip. At the same time,
each panel perimeter strip comprises a generally C-shaped member
configured to reside inside of and extend along an inside portion
of a side surface of a respective wall panel. Further, each panel
perimeter strip has a slot integrally attached to the C-shaped
member adapted to engage and interlock one of the wing members of
the attachment clip, thus connecting a respective non-PV wall panel
to the attachment clip and, thereby, to the wall.
[0029] The hybrid wall panel system also includes one or more
rivets. The rivets are placed along the side surface of the non-PV
wall panels to connect the side surface of a respective wall panel
to a receiving member of a panel perimeter strip.
[0030] The wall panel system may optionally include panel
stiffeners. The panel stiffeners are positioned behind or on the
rear surface of the PV wall panels. Panel stiffeners may also be
placed behind or inside the hollow interior portion of the
respective aluminum wall panels. The panel stiffeners reinforce the
aluminum wall panels and prevent deforming or popping of the
aluminum wall panels.
[0031] The wall panel system may further include a plurality of
infill strips. Each infill strip is preferably fabricated from a
substantially rigid material comprising aluminum, or a combination
of aluminum and polyethylene, or of fire-retardant polyvinyl. Each
of the infill strips is non-sealingly disposed within respective
slots of adjoining panel perimeter strips.
[0032] With the exception of the adhesive connection of the rigid
panels to the tile perimeter strips, the hybrid wall panel system
is held together non-adhesively. Further, the system is ventilated
at least partially through the one or more rivets to permit ingress
and egress of air and moisture to provide a pressure-balanced and
moisture-drained interior environment.
[0033] The above-described systems are configured to allow panels
to be secured to respective bracket assemblies along the wall in
any sequence. Additional wall panels may be attached to the
exterior wall using additional bracket assemblies, attachment clips
and panel perimeter strips.
BRIEF DESCRIPTION OF THE FIGURES
[0034] 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.
[0035] FIG. 1 shows a cross-sectional view of a wall panel
attachment system, in one embodiment. Here, the wall panels are
aluminum panels having edges that are bent inward for connection to
panel perimeter strips.
[0036] FIG. 2 is a cross-sectional view of a panel perimeter strip
used in the attachment system, in one embodiment.
[0037] FIG. 3 is a cross-sectional view of an attachment clip used
in the attachment system, in one embodiment.
[0038] FIG. 4 is a cross-sectional view of a panel stiffener
optionally used in the attachment system, in one embodiment.
[0039] FIG. 5 shows a cross-sectional view of aluminum composite
material (ACM) as may be used in the wall panels.
[0040] FIGS. 6, 7, and 8 show progressive steps in the formation of
an ACM panel for use in the present system, in one embodiment. In
FIG. 8, it can be seen that the opposing edges of the aluminum wall
panel have been bent and then secured to respective panel perimeter
strips using rivets.
[0041] FIG. 9 shows a cross-sectional view of an infill strip as
may be used in the attachment system of FIG. 1.
[0042] FIG. 10 shows an enlarged cross-sectional view of an infill
strip having been received within adjacent panel perimeter strips.
The infill strip covers the attachment clip and fastener.
[0043] FIG. 11 is an elevational view of sub-framing or bracket
assemblies used for mounting a plurality of ACM panels in the
present system, in one arrangement.
[0044] FIG. 12 is a cross-sectional view of a wall panel attachment
system with bracket assemblies, in one embodiment.
[0045] FIGS. 13, 14 and 15 show progressive steps in the
installation of an infill strip in a wall panel attachment system,
according to a first method.
[0046] FIG. 16 shows a view of the installation of lengths of
infill strip in a wall panel attachment system, according to a
second method.
[0047] FIG. 17 shows a view of a finished wall paneled exterior, in
one embodiment. A plurality of wall panels is shown.
[0048] FIG. 18 shows a cross-sectional view of a panel perimeter
strip, in an alternate arrangement.
[0049] FIGS. 19 and 20 show cross-sectional views of two versions
of an alternative panel stiffener.
[0050] FIG. 21 is a cross-sectional view of a photovoltaic (PV)
wall panel attachment system adjacent a non-PV wall panel
attachment system, wherein the exterior surfaces remain flush with
one another.
[0051] FIGS. 22 and 23 provide enlarged views of upper and lower
portions of wall panel attachment systems for supporting a PV
panel. Separate tile perimeter strips are shown.
[0052] FIG. 24 is a plan view of a panel placed on panel perimeter
strips.
[0053] FIG. 25 is a top (or, optionally, side) view of another
photovoltaic (PV) wall panel attachment system. Here, two solar
wall panels are placed on an exterior wall adjacent to one another.
The two solar wall panels are flush.
[0054] FIG. 26 shows cross-sectional views of a plurality of
alternative attachment clips that may be used in the attachment
systems herein, depending on location of the panel to be
installed.
[0055] FIG. 27 shows cross-sectional views of a plurality of
alternative panel perimeter strips that may be used with the
attachment systems herein, depending on location of the panel to be
installed.
[0056] FIG. 28 provides cross-sectional views of alternative infill
strips as may be used in the attachment systems herein.
[0057] FIG. 29 is a perspective view of a rigid panel that may be
adhered to an alternative tile perimeter strip. The rigid panel may
be a porcelain ceramic tile (PCT) wall panel.
[0058] FIG. 30 is a top (or, optionally, a side) view of a
porcelain ceramic tile (PCT) wall panel attachment system, in one
embodiment. Here, two porcelain ceramic wall panels are placed on
an exterior wall adjacent to one another.
[0059] FIG. 31 is a cross-sectional view of a wall panel assembly,
wherein the assembly utilizes a porcelain ceramic tile (PCT) wall
panel attached to panel perimeter strips. The assembly is ready for
hanging.
[0060] FIG. 32 is a cross-sectional view of a PCT wall panel
attachment system at an end of a wall. A porcelain ceramic tile is
shown placed along the exterior of the wall. The attachment system
in this view is ideally suited for use with a curtain wall
sill.
[0061] FIG. 33 is a cross-sectional view of a PCT wall panel
attachment system at an end of a wall, in an alternate embodiment.
A porcelain ceramic tile is again shown placed along the exterior
of the wall. The attachment system in this view is ideally suited
for use with a curtain wall head.
[0062] FIG. 34 is still another cross-sectional view of a PCT wall
panel attachment system at an end of a wall, in an alternate
embodiment. A porcelain ceramic tile is again shown placed along
the exterior of the wall. The attachment system in this view is
ideally suited for use with a ceramic window sill.
DETAILED DESCRIPTION
[0063] Wall panel attachment systems are provided herein. The wall
panel attachment systems employ an extruded aluminum attachment
system for fastening a plurality of panels to a building surface.
The components may be fabricated from a milled or anodized
aluminum. Each system's strength is enhanced by the use of an
extruded perimeter frame design which carries the dead load for the
various panels.
[0064] In the present disclosure, different types of panels are
employed. These include aluminum composite material (ACM) panels,
solar or photovoltaic (PV) panels, and porcelain ceramic tile (PCT)
panels.
[0065] FIG. 1 presents a cross-sectional view of a wall panel
attachment system 10, according to one embodiment. Here, the
attachment system 10 is used to attach ACM panels 32 to the
exterior surface of a wall 100.
[0066] The system 10 is designed to operate in accordance with the
rainscreen principle. This means that the system 10 is designed so
that a wall cavity formed under the individual panels is vented,
resulting in a pressure-equalized system. Controlled moisture
drainage within the system, coupled with this equalized pressure,
contributes to effective, maintenance-free construction. The flow
of air through a wall panel 32 and into a hollow interior 30 behind
the ACM panel 32 is shown at arrows "A."
[0067] The attachment system 10 may be fabricated through an
extrusion process. The extrusion process begins with an aluminum
billet, which is the material from which the profiles are
preferably extruded. The billet must be softened by heat prior to
the extrusion process. The heated billet is placed into an
extrusion press, which represents a powerful hydraulic device
wherein a ram pushes a dummy block. The dummy block, in turn,
forces the softened metal through a precision opening, known as a
die. The die produces the required shapes.
[0068] The extruded parts are cut to specific lengths. The extruded
parts may have a milled or an anodized finish. It is, of course,
understood that the system 10 is not limited by the specific
extrusion process or other method by which the component parts are
manufactured.
[0069] The system 10 includes a panel perimeter strip. FIG. 2
provides a cross-sectional view of an illustrative panel perimeter
strip 14. FIG. 10 provides a cross-sectional view of a pair of
panel perimeter strips 14. In FIG. 10, the panel perimeter strips
14 have been connected to corners of wall panels 32. Connection is
by means of counter-sunk rivets 36. FIG. 10 will be discussed in
further detail below.
[0070] Referring back to FIG. 1, three panel perimeter strips are
seen, with one being marked as 14A. The panel perimeter strips
14/14A are attached to side surfaces of wall panels 32. The wall
panels 32 are preferably fabricated from an aluminum composite
material (ACM). Hollow rivets (numbered as 36 in FIG. 10) are also
shown in FIG. 1, connecting the panel perimeter strips 14/14A to
the panels 32.
[0071] The system 10 also includes an attachment clip 16. FIG. 3
provides a cross-sectional view of an illustrative attachment clip
16. The attachment clip 16 has a central fastening surface, and a
pair of integrally formed wing members. Each wing member extends
outwardly from the central fastening surface in a substantially
symmetrical manner.
[0072] FIG. 10 provides another cross-sectional view of an
attachment clip 16. In FIG. 10, each wing member of the attachment
clip 16 is received by an opposing panel perimeter strip 14. Thus,
the panel perimeter strips 14 are designed to mate together with
the wing members of the attachment clips 16. The custom-designed
extrusion allows for maximum attachment area without foregoing
structural integrity.
[0073] The attachment clip 16 is used on-site to attach the panel
perimeter strips 14 to a building. An exterior building surface is
shown in FIG. 1 at 100. The exterior building surface 100 is above
a building foundation or ground surface 110.
[0074] To install the panel system 10, sub-framing may be
constructed. Preferably, the sub-framing comprises two back-to-back
galvanized steel "L" angles, referred to sometimes herein as
bracket assemblies. FIG. 12 is an enlarged cross-sectional view
showing the system 10 of FIG. 1. In FIG. 12, two "L" angles are
seen at 40. The L-angles 40 serve as brackets that allow the
installer to level the substrate in all three axes before
installation of panel assemblies 34. Preferably, stainless steel
screws 44 are used to connect the L-brackets 40 to the building
surface 100. Further, the L-brackets 40 themselves may be connected
to each other through one or more stainless steel screws 46.
[0075] The bracket assemblies 40 are preferably installed
horizontally at each horizontal joint. FIG. 11 shows a cut-away
elevational view of the sub-framing, or L-brackets 40, as installed
on an exterior building surface 100. It can be seen that a series
of finished ACM panel assemblies 34 have been mounted onto the
exterior building surface 100. Preferably, panel assemblies 34 are
mounted from the bottom of the exterior building surface 100, and
moves up. In this way, the installer may make sure that each row is
level relative to the previous row installed. However, it is
observed here that the finished panel assemblies 34 may
beneficially be installed in any direction or sequence.
[0076] This aspect of the inventions deserves further discussion.
As can be seen in FIG. 11, the L-angle brackets 40 have been placed
along the exterior building surface 100 in horizontal rows. The
finished panel assemblies 34 may be secured to the brackets 40 from
left-to-right, from right-to-left, or even out of order provided
the correct spacing is maintained. Similarly, the L-angle brackets
40 may be placed along the exterior building surface 100 in
vertical rows. The finished panel assemblies 34 may then be secured
to the brackets 40 from bottom-to-top, from top-to-bottom, or out
of order provided the correct spacing is maintained.
[0077] Referring back to FIG. 12, a thin layer of isolation tape 42
may be applied to the back of the aluminum attachment clips 16.
This prevents direct contact between the galvanized steel
sub-framing (bracket assemblies 40) and the corresponding aluminum
attachment clip 16. Thus, in turn, prevents galvanic action
(electrolytic decay of the aluminum) over time. Preferably,
stainless steel self-drilling screws 48 are used to fasten the
aluminum attachment clips 16 to steel sub framing 40. After
determining a logical order of installation, each panel assembly 34
is plumbed and leveled to ensure a tight and concise fit from panel
to panel.
[0078] The individual panels 32 may optionally be supported by a
panel stiffener. FIG. 4 provides a cross-sectional view of a panel
stiffener 18, in one embodiment. In this embodiment, the panel
stiffener 18 comprises a hollow tube having a square profile.
[0079] Such a panel stiffener 18 is desirable on large-sized
panels. The panel stiffeners 18 may be used to prevent the popping
or "oil canning" of the finished panel assemblies 34. As the
individual panels 32 heat up, the panels 32 may expand and make a
popping sound. The stiffeners 18 reinforce the panels 32 to reduce
this effect.
[0080] FIGS. 19 and 20 provide cross-sectional views of panel
stiffeners 18A, 18B, in alternate embodiments. In these
arrangements, the panel stiffeners 18A, 18B are internally
reinforced. This provides greater stability between the exterior
building surface 100 and the panel assemblies 34.
[0081] Where panel stiffeners 18, 18A, 18B are used, the panel
perimeter strip 14 may be adapted to better locate and secure the
stiffener component. A panel perimeter strip 14A having a profile
as shown in FIG. 18 may be advantageous for this purpose. An
extended interior lip 15 of the panel perimeter strip 14A operates
to secure the panel stiffener component.
[0082] Panel stiffeners may be provided in different sizes
depending on the wind pressures to which the panels 34 will be
exposed. A larger width panel stiffener 18B may be advantageous
where there are greater wind loads on the attachment system 10 or
if less deflection on the individual panels 34 is desired. It will
be appreciated that the construction of the panels 32 themselves
also provides a basic level of rigidity, and stiffeners are not
necessarily required.
[0083] The attachment system 10 also includes an infill strip. An
infill strip 38 is shown in the cross-sectional views of FIGS. 1,
10, and 12. An infill strip 38 is also shown in cross-sectional
isolation in FIG. 9. The infill strip is preferably cut to a width
of approximately 11/4'' (32 mm) for a 1/2 (13 mm) joint. The infill
strip 38 replaces the conventional caulk joint, giving the panel
system a clean, maintenance free appearance. The infill strip 38
also is used to hide the fasteners 48 for the attachment clip
16.
[0084] Each attachment clips 16 is designed so as to interlock with
a pair of panel perimeter strips 14 while holding an infill strip
38 securely in place.
[0085] Both the infill strips 38 and the panels 32 are preferably
fabricated from an aluminum composite material ("ACM"). FIGS. 5
through 7 present illustrative cross-sectional views of an ACM
panel 32 undergoing fabrication. The panel 32 may be fabricated
from several layers as described below.
[0086] As shown in FIG. 5, ACM 20 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 sheets
22 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 32 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.
[0087] A finished ACM panel 32 may be fabricated from a flat sheet
of ACM 26 using different types of router and cutting bits 28 (seen
in FIG. 6). After the sheet of ACM 26 has been cut and routed, the
sheet 26 is then bent along the router lines to form the finished
panel 32 (seen in 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 (seen in FIGS. 8 and 10). A
standard panel rivet for this application may be 3/16''
diameter.
[0088] FIG. 8 shows a finished panel assembly 34. Panel perimeter
strips 14 are shown supporting a panel 32. Two rivets 36 are also
shown, preserving through-openings through the panel perimeter
strips 14 and connected panels 32.
[0089] There are various methods to accomplish the routing and
cutting process:
[0090] Method 1
[0091] 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.
[0092] Method 2
[0093] 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.
[0094] Method 3
[0095] 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.
[0096] FIGS. 13 through 16 demonstrate the installation of an
infill strip 38 into an attachment system 10. The infill strips 38
are preferably shipped to a construction site in long lengths, and
are cut to fit on-site. The strips 38 may have a protective plastic
coating, which is then removed from the face of the infill strips
38 before installation.
[0097] The infill strips 38 may be installed one of two ways:
[0098] First, as shown in FIGS. 13 through 15, individual infill
strips 38 may be slipped into a slot 37 before the adjacent panel
is installed. This is of benefit when the edge of the joint is not
accessible, or when the infill strip 38 has a curve or bend in it.
The infill strip 38 is fitted into the space between the panel 32
and the attachment clip 16 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 37 in the panel
edge at the perimeter strip 14A' (FIG. 15).
[0099] Second, and as an alternative method of installation, the
installer can slide the infill strip 38 in from the end. This is
shown in FIG. 16. This allows for a simplified installation of the
finished panels 34. The infill strips 38 are not installed until an
area is complete. This means that panel assemblies 34 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 16 as it is being slid into the joint. To aid in
the sliding of the strips 38, a tool may be used to pull the
leading edge of the strips 38 over the clips (not shown in FIG.
16).
[0100] FIG. 17 presents a perspective view of a finished wall panel
exterior. The finish faces of the panels 32 may have a protective
film 50 to protect against minor abrasions that may occur during
handling and installation. The protective film 50 may be peeled
back from the returns of the panels 32 before installing. To keep
the panels 32 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.
[0101] As can be seen, a dry joint aluminum wall panel attachment
system 10 for attaching wall panels to an exterior building wall is
provided. The attachment system includes a plurality of individual
aluminum-based wall panels 32. Each wall panel has an exterior flat
surface and four side surfaces. At least two of the side surfaces
are bent generally perpendicularly to the exterior flat surface. In
this way, a hollow interior portion 30 is defined.
[0102] The attachment system 10 also includes a plurality of
bracket assemblies. Each bracket assembly is configured to be
fastened to the exterior wall 100. In one aspect, each bracket
assembly comprises two back-to-back L-angle brackets 40 fastened to
each other via connectors 46 to form a generally Z-shaped assembly.
A first end is for attachment to the exterior wall surface 100, and
a second end is for fastening to an attachment clip 16. Preferably,
the bracket assemblies 40 are fabricated from steel for
strength.
[0103] The attachment system 10 also has a plurality of attachment
clips 16. Each clip 16 is preferably fabricated from aluminum and
is configured to be fastened to a respective bracket assembly by a
fastener 48. Preferably, each fastener 48 comprises a threaded
fastener. The attachment clips 16 carry the dead load of the wall
panels 32.
[0104] Each attachment clip 16 has a pair of integrally formed wing
members. Each wing member extends outwardly from the central
fastening surface in a substantially symmetrical manner.
Preferably, isolation tape 42 is applied between the attachment
clips 16 and the respective bracket assemblies.
[0105] The attachment system 10 also includes a plurality of panel
perimeter strips 14. Preferably, each panel perimeter strip 14 is
fabricated from aluminum. Each panel perimeter strip 14 (or,
optionally, 14A) is configured to be fastened to one side surface
of a respective wall panel 32. Further, each panel perimeter strip
14 comprises a generally C-shaped member configured to reside
inside of and extend along an inside portion of a side surface of a
respective wall panel 32, and a receiving member integrally
attached to the C-shaped member configured to extend beyond the
side surface of a wall panel 32 and provide a slot 37 adapted to
engage and interlock one of the wing members of the attachment clip
16, thus operatively connecting a respective wall panel assembly 34
to the attachment clip 16 and thereby to the wall 100.
[0106] The attachment system 10 also includes rivets 36. The rivets
36 are placed along the side surface of the wall panels 32 to
connect the side surface of a respective wall panel 32 to a
receiving member of a panel perimeter strip 14. The rivets 36 are
hollow to permit the ingress and egress of air and moisture through
the hollow interior area 30 behind the panels 32.
[0107] The attachment system 10 further includes a plurality of
infill strips 38. Each infill strip 38 is preferably fabricated
from a substantially rigid material comprising aluminum or aluminum
composite material. Each of the infill strips 38 is non-sealingly
disposed within respective slots 37 of adjoining panel perimeter
strips 14.
[0108] The infill strips 38 are placed between a corresponding
attachment clip 16 and the one or more rivets 36 so as to cover the
fasteners 48. In one aspect, each infill strip 38 is engaged with
the slot 37 of a panel perimeter strip prior to installing an
adjacent wall panel assembly 34. Alternatively, each infill strip
38 may be introduced to the slots 37 of two adjacent panel
perimeter strips 32 after two adjacent wall panel assemblies 34
have been installed.
[0109] The attachment system 10 is held together non-adhesively. In
addition, the attachment system 10 is configured to allow panel
assemblies 34 to be secured to respective panel attachment clips 16
in any sequence.
[0110] The wall panel attachment system 10 may be modified for use
with stiff or rigid panels. In this instance, an adhesive is
applied to a flat surface of a tile perimeter strip. The rigid
panels may be, for example, fabricated from ceramic.
[0111] In one embodiment, it is desirable to integrate the wall
panel attachment system 10 with the ability to generate clean
energy for the building on which the wall panels are mounted. FIG.
21 provides a cross-sectional view of a photovoltaic (PV) wall
panel attachment system 60. The system 60 may be used to attach
multiple PV wall panels 61 to an exterior building wall (such as
wall 100 of FIG. 1) adjacent to ACM panels. The system 60 includes
a plurality of PV wall panels 61 which are attached to a structural
sub-assembly, as will be described below.
[0112] First, bracket assembly 62 is mounted to the exterior
building wall 100. The bracket assembly 62 may comprise one or more
L-angle brackets, and can be configured to accommodate adjacent
panels, as needed. For example, as shown in FIG. 21, an installed
aluminum composite wall panel 32 is shown residing above or
adjacent an installed PV panel 61. The bracket assembly 62 may be
constructed of multiple bracket components affixed to one another
to form a unitary structural foundation or sub-framing for the
remainder of the system 60.
[0113] The bracket assembly 62 shown in FIG. 21 comprises a primary
base bracket 71, a secondary base bracket 72, and a panel mounting
bracket 73, all of which are secured to one another by conventional
fasteners, such as stainless steel screws 46. The primary base
bracket 71 and the secondary base bracket 72 are each secured to
the exterior building wall 100 by fasteners 63, which are
preferably masonry screws. Optionally, a cable guide 64 is attached
to the bracket assembly 62 to permit secure routing of electrical
cables 67 extending from each of the PV wall panels 61. The cables
67 carry electric current generated by the PV panels 61.
[0114] The wall panel attachment system 60 also includes attachment
clips 16. The attachment clips 16 are configured to be fastened to
respective bracket assemblies 62 by a fastener 68 and to carry the
dead loads of the respective PV wall panels 61. The attachment
clips 16 may have a single-wing design as shown in FIG. 21, or a
double-wing design as shown in FIG. 21, depending on the location
along the wall 100 in which they are used.
[0115] FIG. 26 shows a series of cross-sectional views of
attachment clips that may be used in the attachment system 60. A
double-wing design is shown at 16. The double-wing design is used
when multiple solar (or other stiff) panels 61 are being hung
adjacent to one another. The double-wing clips 16 allow panels 61
to be hung in any sequence.
[0116] A single-wing design is shown at 16A. This is actually the
attachment clip used in FIG. 21. The single-wing design 16A may be
utilized when a panel 61 is being installed at an edge of a wall or
adjacent a window sill. The single-wing design 16A may also be
utilized when a panel 61 is being installed adjacent an ACM panel
32, as shown in FIG. 21.
[0117] The wall panel attachment system 60 also includes a
plurality of tile perimeter strips 74. The tile perimeter strips 74
provide lateral support for the PV wall panels 61. The tile
perimeter strips 74 may be placed along horizontal edges of the
panels 61, vertical edges of the panels 61, or both. Further, where
the panels 61 are polygonal bodies having edges that are offset
from vertical and horizontal, the tile perimeter strips 74 may be
angled to support the offset edges.
[0118] Each tile perimeter strip 74 comprises a generally C-shaped
member configured to extend along a rear surface 69 of a respective
PV wall panel 61. Each tile perimeter strip 74 also includes a
receiving member integrally attached to the C-shaped member having
a slot adapted to engage and interlock one of the wing members of
the attachment clip 16, shown best in the enlarged views of FIGS.
22 and 23.
[0119] FIG. 27 shows a series of cross-sectional views of panel
perimeter strips that may be used with the attachment system 60.
The panel perimeter strip 74 shown in FIG. 27 is also used in FIG.
21. The tile perimeter strips 74 provide horizontal support for the
PV wall panels 61.
[0120] The wall panel attachment system 60 may further include one
or more panel stiffeners 18. As shown in FIG. 21, a panel stiffener
18 may be placed in the C-shaped member of the panel perimeter
strip 74 to provide lateral support for an adjacent panel 61. Each
panel stiffener 18 is fixed between the C-shaped members of
opposing tile perimeter strips 74, as shown in FIGS. 22 and 23.
Preferably, the panel stiffeners 18 are connected to the tile
perimeter strips 74 using conventional fasteners 75, and are
positioned such that the left and right edges of the PV wall panel
61 are substantially flush with the panel stiffeners 18.
[0121] It is noted that in the views of FIGS. 21, 22, and 23, a gap
is present between the panel 61 and the stiffener 18. In reality,
this gap is very small, such as only 1 to 7 mm. Therefore, the
panels 61 and the stiffeners 18 may be considered to be
"attached."
[0122] Each PV wall panel 61 is attached to the panel stiffeners 18
and to the tile perimeter strips 74. Preferably, the PV wall panel
61 is bonded to the panel perimeter strips 74 using a structural
silicone adhesive 66. An example of a suitable adhesive 66 is the
983 Silicone Glazing and Curtainwall adhesive/sealant product
manufactured by Dow Corning.
[0123] In a preferred embodiment, a high-density closed-cell foam
tape 65 is applied to either a rear perimeter surface 69 of the PV
wall panel 61, or to the tile perimeter strip 74. The 1/4'' wide by
3/8'' high, high-density, closed-cell foam tape 65 provides spacing
for the necessary thickness of the structural silicone adhesive 66,
as shown in FIG. 24.
[0124] In operation, the high-density closed-cell foam tape 65 may
first be applied to the planar surface of a panel perimeter strip
74. Thereafter, a PV wall panel 61 is held onto or laid on the
panel perimeter strip 74 and, optionally, a panel stiffener 18. A
bead or volume of structural silicone adhesive 66 is then applied
to a void formed between the PV wall panel 61 and tile perimeter
strip 74 outside of the foam tape 65. The void is filled until the
structural silicone adhesive 66 is flush with the exterior
perimeter edges of the tile perimeter strip 74 and the panel 61, as
shown is FIGS. 22 and 23. The high-density, closed-cell foam tape
65 confines the structural silicone adhesive 66 to the tile
perimeter strip 74. The tape 65 also maintains a gap between the
panel perimeter strip 74 and the panel 61 to ensure that that the
electrically active area on the PV wall panel 61 remains
unaffected.
[0125] Structural bonding tape can be used as an alternative to the
structural silicone adhesive 66 and the foam tape 65 when utilizing
tile perimeter strip 74D. One such suitable bonding tape is the VBH
bonding tape manufactured by 3M Company. Preferably, an additional
adhesive 66 is applied to the rear surface periphery of the PV wall
panel 61 in the form of a structural silicone adhesive and sealant,
such as the 983 Silicone Glazing and Curtainwall adhesive/sealant
product manufactured by Dow Corning. In this manner, the PV wall
panel 61 is securely bonded to the structural assembly beneath
it.
[0126] The PV wall panels 61 may be any desired PV panel that is
suitable for use in the desired application. One example of such a
PV panel is the ASI OPAK solar panel manufactured by Schott North
America, Inc., of Elmsford, N.Y.. It is noted that such solar
panels can be very heavy--even up to 60 pounds, depending on
dimensions. Therefore, care should be taken to ensure that a
quality adhesive is used for securing the panels 61 to the panel
perimeter strips 74.
[0127] It will be understood to those of ordinary skill that the
shape and dimensions of the mounting components described above
should permit mounting of the PV wall panels 61 so that their
exterior surfaces may be flush with the adjacent non-solar wall
panels 32. Thus, in FIG. 21, a solar wall panel 61 is placed on an
exterior wall 100 adjacent a non-PV wall panel, e.g., the ACM panel
32.
[0128] It is also understood that the panel systems 60 herein may
also be used with solar wall panels being adjacent to one another.
FIG. 25 is a top view of another photovoltaic (PV) wall attachment
system 60. Here, two solar wall panels 61 are placed on an exterior
wall 100 adjacent to one another. An attachment clip 16 having a
central fastening member and two symmetrically extending wing
members is provided. Further, two tile perimeter strips 74 are
provided. The tile perimeter strips 74 are adhesively connected to
the rear surfaces of the respective solar panels 61 using adhesive
66.
[0129] Through-openings may optionally be provided in the tile
perimeter strips 74. These are shown in FIG. 25 at 77. The
through-openings 77 permit the ingress and egress of air and
moisture behind the solar wall panels 61 to provide a
pressure-balanced and moisture-drained environment.
[0130] The description above for FIGS. 22 through 25 pertain to the
use of solar wall panels with an attachment system 60. The
attachment system 60 allows for the installation of PV panels 61
wherein panel assemblies (panels 61 with panel perimeter strips 74)
may be hung in any sequence. It is noted that modifications of
certain components to the attachment systems 60 may be made. These
include the attachment clip 16, the panel perimeter strip 74, and
the infill strip 38.
[0131] FIG. 26 shows a series of cross-sectional views of
attachment clips that may be used in the attachment system 60. The
first attachment clip 16 is the attachment clip shown in FIG. 3.
The attachment clip is also shown in the attachment system of FIG.
25. The second attachment clip 16A is the attachment clip shown in
the attachment system of FIG. 21. This attachment clip 16A is also
seen at the bottom of FIG. 1.
[0132] It is understood that where panels 61 are placed along a
corner or edge of a wall, some modification of the attachment clip
16 is necessary. The half-clip of 16A is noted above. Additional
attachment clips 16B and 16C are shown. Attachment clip 16B is
illustratively shown being used in FIG. 33, while attachment clip
16C is illustratively shown being used in FIG. 34. Attachment clips
16B and 16C are useful where panels 61 are being installed along a
corner or edge of a wall or adjacent a door frame or window
sill.
[0133] FIG. 27 shows a series of cross-sectional views of panel
perimeter strips that may be used with the attachment system 60.
The first panel perimeter strip 74 is the panel perimeter strip
shown in the attachment systems of FIGS. 21 and 25. However,
modifications to the panel perimeter strip 74 are shown at 74A,
74B, 74C, and 74D. These alternate embodiments may be used to
provide additional structural security to the PV panels. For
example, the panel perimeter strip 74D may be used where the
installer uses structural bonding tape in lieu of the structural
silicone adhesive 66.
[0134] The various panel perimeter strips 74, 74A, 74B, 74C, 74D
may be used to secure stiff panels or tiles to exterior surface of
a building. In this instance, the perimeter strips may be referred
to as tile perimeter strips.
[0135] FIG. 28 provides a series of cross-sectional views of infill
strips as may be used in the attachment system 60. Infill strip 38
is the infill strip shown in FIG. 9. This infill strip is also seen
in the attachment system of FIG. 15. However, modifications to the
infill strip may be made where a different profile for a panel
perimeter strip is employed. Alternate infill strip profiles are
shown at 38Ai, 38Aii, 38B, and 38C.
[0136] Infill strips 38Ai and 38Aii are used when access and
removal panels are required. Infill strip 38B is used when the
panel revealed joint is filled--to various depths or
widths--utilizing the slots created by the tile perimeter strip 74
and the attachment clips 16. Infill strip 38C is used when the
panel revealed joint is desired to be enclosed, utilizing the two
adjoining tile perimeter strips 74 only.
[0137] The description above for FIGS. 1, 12, 21 and 25 relate to a
wall panel attachment system that may be used for the installation
of ACM 32 and solar 61 wall panels, and combinations thereof.
However, the wall panel attachment systems described above may be
used with rigid, non-solar wall panels.
[0138] FIG. 29 provides a perspective view of a flat panel 90 that
may be fastened or adhered to perimeter strips and panel
stiffeners. The illustrative panel 90 is fabricated from a ceramic
material. For purposes of the present disclosure, the terms
"ceramic" or "ceramic material" may include oxides such as alumina
and zirconia. Specific examples include bismuth strontium calcium
copper oxide, silicon aluminium oxynitrides, uranium oxide, yttrium
barium copper oxide, zinc oxide, and zirconium dioxide. "Ceramic"
may also include non-oxides such as carbides, borides, nitrides and
silicides. Specific examples include titanium carbide, silicon
carbide, boron nitride, magnesium diboride, and silicon nitride.
The term "ceramic" also includes composites, meaning particulate
reinforced, combinations of oxides and non-oxides. Additional
specific examples of ceramics include barium titanate, strontium
titanate, ferrite, and lead zierconate titanate.
[0139] A wall panel attachment system 80 is offered herein, wherein
the panels are fabricated from ceramic. A preferred ceramic
material is porcelain. Porcelain is a ceramic material made by
heating raw materials, generally including clay in the form of
kaolin, in a kiln to temperatures between 1,200.degree. C.
(2,192.degree. F.) and 1,400.degree. C. (2,552.degree. F.).
Porcelain may be fabricated as tiles, referred to as porcelain
ceramic tile, or PCT. In this instance, PCT may also be referred to
herein as a "cladding material."
[0140] FIG. 30 is a top (or, alternatively, a side) cross-sectional
view of a porcelain ceramic tile (PCT) wall panel attachment system
80, in one embodiment. Here, two porcelain ceramic wall panels 81
are placed on an exterior wall 100 adjacent to one another.
[0141] In the attachment systems 80 of FIG. 30, a plurality of
ceramic tiles 81 may be installed onto a wall in any sequence.
However, it is noted that the system 80 of FIG. 30 is essentially
the same as the system 60 shown in FIG. 25, but without the
electrical cables 67, and wherein the panels are ceramic rather
than solar wall panels.
[0142] Each ceramic tile, or panel 81, may be 2.5 mm to 3.00 mm in
width. Each panel 81 may further be reinforced using a 0.5 mm to
1.0 mm laminate of fiberglass on one side, and a 0.5 mm to 1.0 mm
laminate of fiberglass on the opposing side.
[0143] As with the photovoltaic (PV) wall panel attachment system
60, the PCT attachment system 80 utilizes a bracket assembly 62 to
support the panel 81. The bracket assembly 62 is mounted to the
exterior building wall 100. The bracket assembly 62 may comprise
one or more L-angle brackets 72, 73, and can be configured to
accommodate adjacent panels, as needed. The brackets 72, 73 may be
two back-to-back galvanized steel "L" angles. The bracket assembly
62 may be constructed of multiple bracket components affixed to one
another to form a unitary structural foundation or sub-framing for
the remainder of the system 80.
[0144] The bracket assembly 62 shown in FIG. 30 comprises a wall
bracket 72 and a panel mounting bracket 73. These brackets 72, 73
are secured to one another by conventional fasteners, such as
stainless steel screws 46. The L-angle brackets 72, 73 serve as
brackets that allow the installer to level the substrate in three
axes before installation of PCT panels 81. The sub-framing
installation may be the same as for the ACM panels 32.
[0145] Attachment clips 16 are configured to be fastened to
respective panel attachment systems 80 by a fastener 68 and to
carry the dead loads of the respective PCT wall panels 81. The
attachment clip 16 shown in FIG. 30 uses a double-wing design. Tile
perimeter strips 74 are also shown in FIG. 30, attached to the
ceramic panels 81. The perimeter strips 74 include a
through-opening 77. The through-opening permits the ingress and
egress of air and moisture behind the ceramic wall panel 81 to
provide a pressure-balanced and moisture-drained environment.
However, the hollow rivets 36 from ACM system 10 are not
needed.
[0146] The PCT wall panel attachment system 80 also includes a
high-density, closed-cell foam tape 85. The tape 85 is, and acts in
the same manner as, the foam tape 65 as shown in FIG. 25. The tape
85 may be applied to either the rear perimeter surface 89 of the
PCT wall panel 81 or to the planar surface of the tile perimeter
strip 74. The high-density, closed-cell foam tape 85 creates
spacing for the necessary thickness needed for the adhesive 86.
This, again, is in the form of a structural silicone adhesive and
sealant, such as the 983 Silicone Glazing and Curtainwall
adhesive/sealant product manufactured by Dow Corning. In this
manner, the PCT wall panel 81 is securely bonded to the structural
assembly beneath it. The foam tape 85 also acts as a backstop as
silicone adhesive is squeezed into the gap between the panel
perimeter strip 74 and a rear surface 89 of the ceramic panel 81.
This assembly process is essentially identical to that of the PV
wall panel attachment system 60.
[0147] It is noted that in most cases, the use of the peripheral
structural silicone adhesive 66 is adequate. For some panels, the
operator may choose to add a bonding tape (shown at 95 in FIG. 33).
For larger panels, the operator may further add structural silicone
adhesive 86 in the gap between the stiffeners 18 and the rear 89 of
the panels 81. Also, structural bonding tape may be used as an
alternative to the silicone adhesive 86 and the high-density closed
foam tape 85 when utilizing tile perimeter strip 74A.
[0148] FIG. 31 provides a cross-sectional view of a wall panel
assembly 84. The assembly 84 utilizes a porcelain ceramic tile
(PCT) wall panel 81 attached to panel perimeter strips 74. The
assembly 84 is ready for hanging as part of the system 80 of FIG.
30.
[0149] FIGS. 30 and 31 demonstrate the use of porcelain ceramic
tile (PCT), as a cladding material that can be integrated in a wall
panel attachment system 80. The attachment system 80 allows
individual panels to be hung on the exterior wall of a building in
any sequence. The attachment system 80 is generally used for
placing tiles in the center portion of a wall, as indicated with
panel assemblies 34 in FIG. 11. Where placing panel assemblies
along an edge, corner, or window, a modification is made to the
attachment clip, as shown below in FIGS. 32, 33 and 34.
[0150] FIG. 32 is a cross-sectional view of a PCT wall panel
attachment system 80' at an end of a wall 100. A porcelain ceramic
tile 81 is shown placed along the exterior of the wall 100.
Flashing is indicated at 92 at the end of the wall 100. The
attachment system 80' is ideally suited for use with a curtain wall
sill (not shown).
[0151] The attachment system 80' uses several of the same items as
the photovoltaic (PV) wall attachment system 60 of FIG. 21. In this
respect, the PCT attachment system 80' includes a bracket assembly
62. The bracket assembly 62 may comprise one or more L-angle
brackets. Here, the bracket assembly 62 comprises a wall bracket 72
and a panel mounting bracket 73. The brackets 72, 73 are affixed to
one another by connector screws 46 to form a unitary structural
foundation or sub-framing for the remainder of the system 81'.
[0152] The wall bracket 72 and the panel mounting bracket 73 are
each secured to the exterior building wall 100 by one or more
fasteners 63. Fastener 63 seen in FIG. 32 is preferably a masonry
screw.
[0153] The PCT wall panel attachment system 80' utilizes an
attachment clip and a panel perimeter strip. The attachment clip is
the attachment clip 16A from FIG. 26, while the panel perimeter
strip is the panel perimeter strip 74 from FIG. 27. It can be seen
that the panel perimeter strip 74 includes a through-opening 77.
The through-opening permits the ingress and egress of air and
moisture behind the ceramic wall panel 81 to provide a
pressure-balanced and moisture-drained environment.
[0154] The PCT wall panel attachment system 80' also includes a
closed-cell foam tape 85, such as neoprene. The tape is 85 is
applied to the rear perimeter surface 89 of the PCT wall panel 81
to create spacing. The PCT wall panel attachment system 80' further
includes an additional adhesive 86 applied to the rear surface
periphery 89 of the PCT wall panel 81. This, again, is in the form
of a structural silicone adhesive and sealant, such as the 983
Silicone Glazing and Curtainwall adhesive/sealant product
manufactured by Dow Corning. In this manner, the PCT wall panel 81
is securely bonded to the structural assembly beneath it.
[0155] FIG. 33 is a cross-sectional view of a PCT wall panel
attachment system 80'' at an end of a wall 100, in yet another
alternate embodiment. A porcelain ceramic tile 81 is again shown
placed along the exterior of the wall 100. The attachment system
80'' is ideally suited for use with a curtain wall head (not
shown).
[0156] The PCT attachment system 80'' also includes the wall
mounting brackets 72, 73, the one or more fasteners 63, and the
connector screws 46. The PCT wall panel attachment system 80'' also
utilizes an attachment clip and a panel perimeter strip. The
attachment clip is the attachment clip 16B from FIG. 26, while the
panel perimeter strip is the tile perimeter strip 74A from FIG. 27.
The tile perimeter strip 74A includes the through-opening 77 to
permit the ingress and egress of air and moisture behind the
ceramic wall panel 81.
[0157] The PCT attachment system 80'' shown in FIG. 33 does not use
tape 85 and structural silicone adhesive 86; instead, an optional
thin sheet 94 is placed along the outside flat surface of the tile
perimeter strip 74A. The sheet is fabricated from anodized aluminum
or other metallic material. The sheet 94 may be, for example,
pre-painted galvanized steel. The sheet 94 is secured to the
perimeter strip 74A by counter-sunk rivets (not shown). Strips of
bonding tape 95 are then placed between the sheet 94 and the
ceramic tile 81 in order to adhere the ceramic tile 81 to the
attachment system 80''.
[0158] The use of the sheet steel 94 is particularly beneficial
when the tiles 81 are large, such as greater than 25 square feet in
area. The sheet steel 94 is "picture framed" along and within the
perimeter strip 74A, and provides back support for the ceramic
tiles 81. This, in turn, prevents the tile 81 from shattering in
the unlikely (but nevertheless possible) event that some object
strikes the tile 81 after the attachment system has been installed
on the side of a building, and breaks the tile 81.
[0159] FIG. 34 is still another cross-sectional view of a PCT wall
panel attachment system 80''' at an end of a wall 100, in an
alternate embodiment. A porcelain ceramic tile 81 is again shown
placed along the exterior of the wall 100. The attachment system
80''' is ideally suited for abutment with a ceramic window sill
(not shown).
[0160] The PCT attachment system 80''' also includes the wall
mounting bracket 72. Tape 85 and adhesive 86 are also employed. The
PCT wall panel attachment system 80''' also utilizes an attachment
clip and a panel perimeter strip. The attachment clip is the
attachment clip 16C from FIG. 26, while the panel perimeter strip
is the panel perimeter strip 74 from FIG. 27. The panel perimeter
strip 74 need not include the through-opening 77.
[0161] As can be seen, different attachment clips 16A, 16B, 16C are
used in FIGS. 32, 33, and 34. Each of these attachment clips 16A,
16B, 16C is configured to be fastened to respective panel
attachment systems 80', 80'', 80''' by a fastener 68 and to carry
the dead loads of the respective PCT wall panels 81.
[0162] 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.
* * * * *