U.S. patent application number 13/873310 was filed with the patent office on 2013-11-07 for vented wall girts.
This patent application is currently assigned to Garland Industries, Inc.. The applicant listed for this patent is GARLAND INDUSTRIES, INC.. Invention is credited to Frank Resso.
Application Number | 20130291465 13/873310 |
Document ID | / |
Family ID | 49511483 |
Filed Date | 2013-11-07 |
United States Patent
Application |
20130291465 |
Kind Code |
A1 |
Resso; Frank |
November 7, 2013 |
VENTED WALL GIRTS
Abstract
The invention is directed to an improved sub-structural wall
construction component which provides support for exterior building
cladding materials, allows for air ventilation to aid in drying the
exterior wall cavity, and allows for drainage of incidental
moisture that may infiltrate into the exterior wall cavity.
Inventors: |
Resso; Frank; (Tucker,
GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GARLAND INDUSTRIES, INC. |
Cleveland |
OH |
US |
|
|
Assignee: |
Garland Industries, Inc.
Cleveland
OH
|
Family ID: |
49511483 |
Appl. No.: |
13/873310 |
Filed: |
April 30, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61642655 |
May 4, 2012 |
|
|
|
Current U.S.
Class: |
52/302.1 ;
52/745.1 |
Current CPC
Class: |
E04F 13/0805 20130101;
E04F 13/12 20130101; E04F 13/007 20130101 |
Class at
Publication: |
52/302.1 ;
52/745.1 |
International
Class: |
E04F 13/00 20060101
E04F013/00 |
Claims
1. A sub-structural wall construction component that includes a)
one or more bottom flange elements, b) a top flange element, and c)
one or more vented web elements.
2. The sub-structural wall construction component as defined in
claim 1, including first and second bottom flange elements and
first and second vented web elements, a first edge of said first
vented web element is connected to a first edge of said top flange
element, a second edge of said first vented web element is
connected to a first edge of said first bottom flange element, a
first edge of said second vented web element is connected to a
second edge of said top flange element, and a second edge of said
second vented web element is connected to a first edge of said
second bottom flange element.
3. The sub-structural wall construction component as defined in
claim 1, wherein a majority of a top surface of at least one of
said bottom flange elements is located in a plane that is generally
parallel to a top surface of said top flange element.
4. The sub-structural wall construction component as defined in
claim 1, wherein at least one of said bottom flange elements
includes a plurality of holes.
5. The sub-structural wall construction component as defined in
claim 1, wherein said top flange element is generally a flat
structure wherein a top surface generally lies in a single
plane.
6. The sub-structural wall construction component as defined in
claim 1, wherein at least a portion of a top surface of at least
one of said vented web elements lies in a plane that is
non-parallel to a plane of a top surface of said top flange element
and/or a top surface of at least one of said bottom flange
elements.
7. The sub-structural wall construction component as defined in
claim 1, wherein at least a portion of a top surface of at least
one of said vented web elements angles upwardly from a top surface
of at least one of said bottom flange elements at an angle of about
5.degree.-185.degree..
8. The sub-structural wall construction component as defined in
claim 7, including first and second vented web elements, at least a
portion of a top surface of each of said vented web elements are
parallel to one another and/or angle toward one another.
9. The sub-structural wall construction component as defined in
claim 1, wherein at least one of said vented web elements includes
a plurality of openings.
10. The sub-structural wall construction component as defined in
claim 9, wherein a surface area of said openings on said vented web
elements is less than 70% of a total surface area of a top surface
of said vented web element.
11. The sub-structural wall construction component as defined in
claim 1, wherein a top surface of said top flange element has a
width that is greater than a width of a top surface of at least one
of said vented web elements.
12. The sub-structural wall construction component as defined in
claim 1, wherein a top surface of said top flange element has a
width that is greater than a width of a top surface of at least one
of said bottom flange elements.
13. The sub-structural wall construction component as defined in
claim 1, wherein a top surface of said top flange element has a
width that is greater than a combined width of a top surface of at
least one of said bottom flange elements and a top surface of at
least one of said vented web elements.
14. The sub-structural wall construction component as defined in
claim 1, wherein a top surface of at least one of said bottom
flange elements has a width that is generally greater than a width
of a top surface of at least one of said vented web elements.
15. The sub-structural wall construction component as defined in
claim 1, wherein a top surface of the top flange element is
elevated above a top surface of at least one of said bottom flange
elements.
16. The sub-structural wall construction component as defined in
claim 1, including a stiffener element on one or more of said
bottom flange elements.
17. A sub-structural wall construction component that includes
first and second bottom flange elements, a top flange element, and
first and second vented web elements, a first edge of said first
vented web element is connected to a first edge of said top flange
element, a second edge of said first vented web element is
connected to a first edge of said first bottom flange element, a
first edge of said second vented web element is connected to a
second edge of said top flange element, and a second edge of said
second vented web element is connected to a first edge of said
second bottom flange element, a majority of a top surface of said
first and second vented web elements lies in a plane that is
non-parallel to a plane of a top surface of said top flange
element, a majority of a top surface of said first and second
vented web elements lies in a plane that is non-parallel to a plane
of a top surface of said first and second bottom flange elements, a
majority of said top surface of said first vented web element
angles upwardly from said top surface of said first bottom flange
element at an angle of about 50.degree.-80.degree., a majority of
said top surface of said second vented web element angles upwardly
from said top surface of said second bottom flange element at an
angle of about 50.degree.-80.degree., a majority of said top
surface of each of said vented web elements angle toward one
another, said first and second vented web elements each include a
plurality of openings, a surface area of said openings on said
first vented web element is less than 50% of a total surface area
of said top surface of said first vented web element, a surface
area of said openings on said second vented web element is less
than 50% of a total surface area of said top surface of said second
vented web element.
18. The sub-structural wall construction component as defined in
claim 17, wherein said top surface of said top flange element has a
width that is greater than a width of said top surface of at least
one of said vented web elements, said top surface of said top
flange element has a width that is greater than a width of said top
surface of at least one of said bottom flange elements.
19. The sub-structural wall construction component as defined in
claim 17, including a stiffener element on one or more of said
bottom flange elements.
20. A method providing support for exterior building cladding
materials and to allow for air ventilation to aid in drying of an
exterior wall cavity and to allow for drainage of incidental
moisture that may infiltrate into the exterior wall cavity that is
formed between the cladding materials and the exterior surface of
the building comprising: a. providing cladding material; b.
providing a sub-structural wall construction component, said
sub-structural wall construction component including a) one or more
bottom flange elements, b) a top flange element, and c) one or more
vented web elements; c. securing said sub-structural wall
construction component so said exterior surface of the building by
inserting at least one fastener through said one or more bottom
flange elements; and, d. securing said cladding materials to said
top flange element of said sub-structural wall construction
component such that an interior surface of said cladding materials
are caused to be spaced from said exterior surface of the building
by said sub-structural wall construction component.
Description
[0001] The present invention claims priority on U.S. Provisional
Patent Application Ser. No. 61/642,655, filed May 4, 2012, which is
incorporated herein.
[0002] The present invention is directed to the building industry,
particularly to siding systems for buildings, and more particularly
to a ventilation and/or drainage system that provides support for
metal and/or wood panel exterior cladding materials.
BACKGROUND OF INVENTION
[0003] For a number of decades, recent building construction
techniques have sought to create a perfect seal between the
exterior and interior environments at the exposed exterior cladding
material of a building's wall assembly. Examples of such
arrangement are metal panels with sealed and caulked joints, brick
and masonry treated with sealing compounds, and other materials
that are expected to completely and perfectly seal the exterior of
a building's wall surfaces.
[0004] Recently, especially over the last decade, an older wall
construction technique has been reintroduced as an alternate, and
in many cases, results in superior method of design and
construction of building exterior wall assemblies. Possibly tracing
its inception to 19.sup.th century "two-stage weather tightening"
techniques of the Scandinavian region, this competing method of
exterior wall construction is currently commonly known as a
"Rainscreen Wall" design. In many instances, the same general
design and construction technique is also referred to as "cavity
wall" or "open joint" wall construction.
[0005] In the modern era, the Alcoa Building of Pittsburgh, Pa.
(now the Regional Enterprise Tower), built in 1953, may be the
first modern commercial example of a structure purposely designed
in accordance with the "Rainscreen Wall" principle. In 1971, the
American Architectural Manufacturers' Association published its
first document regarding guidelines for Rainscreen Wall systems.
Finally, in 2008, the U.S. Department for Communities and Local
Governments had included "Rainscreen Wall" principles as an
"innovative" design method.
[0006] The Rainscreen Design Principle
[0007] There are a number of ways in which the Rainscreen Wall
design principle differs from traditional face-sealed building
facade design. In its most basic definition, a Rainscreen Wall
assembly consists of the following elements:
[0008] a. An exterior cladding material, such as metal panels,
glazing, masonry, wood panels, clay panels, ceramic panels,
cementitious panels, stone panels, polymeric exterior cladding
system or other material to provide resistance to wind, impact, and
radiation. The exterior cladding is intended to have some small
amount of porosity, allowing only a minimal amount of moisture to
infiltrate the wall cavity.
[0009] b. A drainage plane behind the exterior cladding system,
most often acting as both an air and water barrier between the
exterior wall cavity and the interior controlled space. The
drainage plane may be impermeable to water vapor diffusion or may
have properties making it slightly to extremely permeable with
respect to water vapor diffusion.
[0010] c. An airspace between the exterior cladding material and
the drainage plane. This airspace, in conjunction with requisite
openings in the exterior cladding (unsealed joints and/or designed
air intake-exhaust vents) serves to allow for air convection to
promote drying of the exterior wall cavity. The airspace also acts
as a barrier to capillary, kinetic, and gravity forces that might
otherwise drive exterior infiltrating moisture into contact with
the concealed drainage plane. It is a widely held assumption that a
1-inch (25 mm) airspace is sufficient to prevent most wind driven
rain from contacting the drainage plane.
[0011] d. Various flashings and weep holes are generally necessary
to direct moisture from the drainage plane across the airspace and
to the exterior of the wall system. Flashings are also generally
necessary at fenestration openings such as doors and windows.
[0012] e. Continuous insulation, while optional, is frequently
included in the exterior wall cavity, directly in contact with the
exterior face of the drainage plane.
[0013] f. A structural back-up wall is the element on the inbound
face of the air barrier that provides load-bearing support for the
walls, the floor, ceiling, and roof structure above, and provides a
finished interior surface for the interior spaces. Commonly, the
structural back-up wall can be comprised of either a) load-bearing
steel studs with gypsum wallboard applied to both faces; b) a
structural steel or concrete frame in-filled with non-load bearing
studs with gypsum wallboard applied to both faces of the steel
studs; or, c) a masonry wall (most commonly concrete block) with
interior wood or metal furring with gypsum wallboard applied to the
interior face of the furring. The structural back-up wall may or
may not contain insulation materials.
[0014] Problems Associated with Constructing an Airspace in a
Rainscreen Wall Assembly
[0015] Walls designed according to Rainscreen Wall design
principles perform well, as compared to traditional face sealed
wall systems, due to the redundant methods of actively managing
moisture infiltration in the wall system. While the airspace in the
exterior cavity wall is a key element structure in a functioning
Rainscreen Wall design wall system, it is a difficult structure to
construct in a practical and/or effective manner. For instance,
when the exterior cladding material is a brick veneer, the veneer
must be secured to the structural back-up wall which is usually
several inches from the interior face of the brick veneer. Such
securing arrangement used to be accomplished by continuous
horizontal steel ledger angles placed every few courses of brick
veneer. However, the ledger angles didn't allow for vertical air
flow in the airspace.
[0016] Recently, the current "best practice" replaces the ledger
angles with discontinuous steel "brick ties." The general design of
the brick ties consists of one leg of a steel angle attached to the
structural back-up wall, and the other leg of the steel angle
extending across the airspace and embedded into the mortar joint of
the exterior brick veneer. In theory, this brick tie does create an
airspace in the exterior cavity wall. However, in practice, the
brick tie arrangement i) makes the installation of the drainage
plane and continuous insulation difficult, ii) creates significant
energy loss due to thermal bridging across the continuous
insulation, and iii) exacerbates the blockage of air circulation
due to mortar drippings catching and accumulating on the brick
ties.
[0017] There are, likewise, difficulties in constructing a
practical and effective airspace in wall systems which include
metal or wood panels as the exterior cladding material. Whereas
some brick, stone, and masonry veneer exterior cladding materials
can support their own weight (brick ties are utilized in these
systems to allow the veneer to resist lateral loads such as those
imposed by wind or seismic activity), most metal or wood panel
exterior cladding systems rely on some system of framing, furring,
or structural sheathing to support the weight of the metal or wood
panels, as well as to transfer lateral loads to the structural
back-up wall. Similar to the ledger angle used with brick veneer,
these panel support systems most often prevent air circulation in
the exterior wall cavity and act as thermal bridges, causing
significant losses in the effectiveness of thermal insulation.
[0018] Some arrangements exist which consist of a discontinuous
angle (similar to a brick tie) attached to the structural back-up
wall and extending through the continuous insulation, and a
continuous furring angle, channel, or zee shape attached to the
discontinuous angle. This arrangement, while better than continuous
metal shapes, generally still results in more than a 10% loss in
effective thermal insulation value due to thermal bridging of the
discontinuous angles and, many times, restricts air circulation in
the exterior cavity due to partial blockage by the continuous
furring member. Furthermore, these arrangements generally result in
the webs and/or flanges of the furring members and/or discontinuous
angles being oriented along the true horizontal plane, which can
then accumulate water. Water accumulation on these members can slow
or prevent drainage via the flashings and weep holes, and can lead
to the deterioration of the furring members and discontinuous
angles.
[0019] There exists in the prior art certain innovative methods of
improving the performance or practicality of supporting metal or
wood panels while maintaining an open air ventilation and drainage
space. One such system is offered by Knight Wall. The most notable
disadvantage of this system, and others like it, is that it
requires the installation of both vertical and horizontal furring
components, and at least one metal furring surface is aligned on
the horizontal plane which can accumulate water.
[0020] In view of the current state of the prior art, there remains
a need for a ventilation and/or drainage system that provides
support for exterior cladding materials.
SUMMARY OF THE INVENTION
[0021] The invention disclosed herein is an improved design that is
superior to all prior art as a practical and effective means of
creating a ventilation and drainage airspace while providing
support for cladding materials. The present invention is directed
to a sub-structural wall construction component (e.g., vented girt)
that is designed to create a ventilation and drainage airspace
while providing support for cladding materials, such as, but not
limited to, wood, metal, clay, ceramic, cementitious, stone, or
polymeric exterior cladding system materials. The sub-structural
wall construction component can be partially or fully formed of a
metal material (e.g., tin, stainless steel, copper, steel, coated
steel [galvanized, painted, etc.], aluminum [painted or bare],
bronze, zinc, or other metals or metal alloys etc.); however, it
can be appreciated that the sub-structural wall construction
component can be formed form other or additional materials (e.g.,
composite materials, plastic, fiber reinforced materials, etc.).
The sub-structural wall construction component can be formed of one
or more pieces of material. In one non-limiting configuration, the
sub-structural wall construction component is formed of a single
piece of material; however, this is not required. The
sub-structural wall construction component can be formed by one or
more process (e.g., cold forming, hot forming, extruded, molded,
stamped, etc.). In one non-limiting arrangement, the sub-structural
wall construction component is formed of a metal material that is
cold formed from a sheet of metal material; however, this is not
required. In such a process, the sub-structural wall construction
component is formed into the desired profile folding, press brake,
roll forming, or by other means. The sub-structural wall
construction component can be punched and/or lanced by use of
mechanical dies, drills, laser cutting, water jet, plasma cutting,
or other means; however, this is not required. The sub-structural
wall construction component can be linearly installed in either a
vertical orientation, horizontal orientation, or some other
orientation.
[0022] In one non-limiting aspect of the present invention, the
sub-structural wall construction component includes a) one or more
bottom flange elements, b) a top flange element, and c) one or more
vented web elements. In one non-limiting design, the sub-structural
wall construction component includes two bottom flange elements;
however, this is not required.
[0023] In another and/or alternative aspect of the present
invention, the one or more bottom flange elements are designed to
mount the sub-structural wall construction component to a building
structure (e.g., wall, ceiling, roof, etc.). When the
sub-structural wall construction component includes two or more
bottom flange elements, the size, shape, thickness, width and/or
material can be the same or different for each of the bottom flange
elements. In one non-limiting configuration, the sub-structural
wall construction component includes two bottom flange elements
that have the same size, shape, thickness, width and material;
however, this is not required. One or more of the bottom flange
elements are oriented such that a portion or the entire top surface
of the one or more of the bottom flange elements are located in a
plane that is generally parallel to the top surface of the top
flange element; however, this is not required. In one non-limiting
configuration, a majority or the entire top surface of the one or
more of the bottom flange elements are located in a plane that is
generally parallel to the top surface of the top flange element;
however, this is not required. In another non-limiting
configuration, a bottom flange element is connected along one edge
to one vented web element; however, this is not required. The one
or more bottom flange elements can optionally include one or more
holes (e.g., punched or stamped holes, etc.) for alignment and/or
ease of installing fasteners; however, this is not required.
[0024] In still another and/or alternative aspect of the present
invention, the top flange element is generally a solid, un-punched
surface; however, the top flange element can include one or more
openings. The top flange element is generally formed of a single
piece of material; however, this is not required. The top flange
element is generally a flat structure wherein the top surface
generally lies in a single plane; however, this is not required.
For instance, the top surface of the top flange element can have an
arcuate shape or some other shape; however, this is not required.
The top flange element is generally connected to an edge of each of
the vented web elements. The top surface of the top flange element
is generally oriented in the vertical plane (plumb with respect to
the ground); however, this is not required. One non-limiting
purpose of the top flange element is to function as a mounting
surface for the exterior cladding material/system. The top flange
element may or may not have punched holes for alignment and/or ease
of installing fasteners. The top flange element is generally formed
of the same material and/or has the same material thickness as the
material used to form the one or more bottom flange elements and/or
one or more vented web elements; however, this is not required.
[0025] In yet another and/or alternative aspect of the present
invention, the one or more vented web elements are secured to the
top flange element and/or bottom flange element. In one
non-limiting configuration, one edge of a vented web element is
connected to an edge of the top flange element and another edge of
the vented web element is connected to an edge of one of the bottom
flange elements. Generally the sub-structural wall construction
component includes two vented web elements; however, this is not
required. In one non-limiting configuration of the sub-structural
wall construction component, a first edge of a first vented web
element is connected to a first edge of the top flange element and
the second edge of the first vented web element is connected to a
first edge of the first bottom flange element, and a first edge of
a second vented web element is connected to a second edge of the
top flange element and the second edge of the second vented web
element is connected to a first edge of the second bottom flange
element. At least a portion of the top surface of one or more of
the vented web elements lies in a plane that is non-parallel to the
plane of the top surface of the top flange element and/or the top
surface of the one or more bottom flange elements. A majority or
all of the vented web elements are generally created at a
non-orthogonal angle with respect to the top flange element and the
bottom flange element; however, this is not required. In one
non-limiting arrangement, at least a portion of the top surface of
one or more of the vented web elements angle upwardly from the top
surface of the one or more bottom flange elements at an angle of
about 5.degree.-185.degree., typically 15.degree.-165.degree., more
typically about 30.degree.-150.degree. and, still more typically,
about 60.degree.-120.degree.. When two or more vented web elements
are used, the upward angle can be the same or different. In one
non-limiting configuration, the sub-structural wall construction
component includes two vented web elements and at least a portion
of the top surface of each of the vented web elements angle toward
one another. In another and/or alternative non-limiting
configuration, the sub-structural wall construction component
includes two vented web elements and at least a portion of the top
surface of each of the vented web elements are parallel to one
another. In still another and/or alternative non-limiting
configuration, the sub-structural wall construction component
includes two vented web elements and at least a portion of the top
surface of each of the vented web elements angle away from one
another. One non-limiting purpose of the upward angle of the one or
more vented web elements is that when the sub-structural wall
construction component is linearly placed in a horizontal
orientation on a building structure, at least a portion or the
entire vented web element will not be aligned with a plane parallel
to the ground; thus, the sub-structural wall construction component
will promote drainage of liquid moisture and be less prone to
accumulation of moisture on any vented web element once the
sub-structural wall construction component is mounted to a building
structure. The one or more openings in the vented web elements can
be formed by stamping or punching (a slug of metal material
removed), lanced (the metal material is pierced and displaced, but
not removed), and/or by some other or additional process so as to
form one or more holes/vents in the vented web elements to allow
both air and water to pass through the vented web elements. As can
be appreciated, the one or more openings can be formed by other
methods (casting, molding, etc.). The size, shape and/or number of
openings in the vented web elements are non-limiting. The
orientation of the one or more openings in the vented web elements
is non-limiting. Generally, each of the vented web elements
includes a plurality of openings. Generally, the surface area of
the openings on the vented web elements is less than 70% of the
total surface area of the top surface of the vented web element,
typically the surface area of the openings on the vented web
elements is less than 50% of the total surface area of the top
surface of the vented web element and, more typically, the surface
area of the openings on the vented web elements is less than 40% of
the total surface area of the top surface of the vented web
element.
[0026] In still yet another and/or alternative aspect of the
present invention, the top surface of the top flange element has a
width that is generally greater than a width of the top surface of
at least one of the vented web elements; however, this is not
required. In one non-limiting configuration, the top surface of the
top flange element has a width that is at least about 150% greater
than a width of the top surface of at least one of the vented web
elements, typically the top surface of the top flange element has a
width that is at least about 200% greater than a width of the top
surface of at least one of the vented web elements and, more
typically, the top surface of the top flange element has a width
that is at least about 250% greater than a width of the top surface
of at least one of the vented web elements; however, this is not
required. In another and/or alternative non-limiting embodiment of
the invention, the top surface of the top flange element has a
width that is generally greater than a width of the top surface of
at least one of the bottom flange elements; however, this is not
required. In one non-limiting configuration, the top surface of the
top flange element has a width that is at least about 110% greater
than a width of the top surface of at least one of the bottom
flange elements, typically the top surface of the top flange
element has a width that is at least about 140% greater than a
width of the top surface of at least one of the bottom flange
elements and, more typically, the top surface of the top flange
element has a width that is at least about 150% greater than a
width of the top surface of at least one of the bottom flange
elements; however, this is not required. In still another and/or
alternative non-limiting embodiment of the invention, the top
surface of the top flange element has a width that is generally
greater than a combined width of the top surface of at least one of
the bottom flange elements and top surface of at least one of the
vented web elements; however, this is not required. In still yet
another and/or alternative non-limiting embodiment of the
invention, the top surface of at least one of the bottom flange
elements has a width that is generally greater than a width of the
top surface of at least one of the vented web elements; however,
this is not required. In one non-limiting configuration, the top
surface of at least one of the bottom flange elements has a width
that is at least about 110% greater than a width of the top surface
of at least one of the vented web elements, typically the top
surface of at least one of the bottom flange elements has a width
that is at least about 130% greater than a width of the top surface
of at least one of the vented web elements and, more typically, the
top surface of at least one of the bottom flange elements has a
width that is at least about 150% greater than a width of the top
surface of at least one of the vented web elements; however, this
is not required. In another and/or alternative non-limiting
embodiment of the invention, the top surface of the top flange
element is elevated above the top surface of at least one of the
bottom flange elements. Generally, the top surface of the top
flange element is elevated above the top surface of at least one of
the bottom flange elements at a distance of at least about 0.25
inches, typically at least about 0.4 inches, more typically at
least about 0.5 inches and, still more typically, at least about
0.75 inches.
[0027] In another and/or alternative aspect of the present
invention, one or more of the bottom flange elements include one or
more stiffener elements; however, this is not required. The
configuration of the one or more stiffener elements, when used, is
non-limiting. For example, the stiffener element can have the
configuration of a short lip, hem, rib, return, etc. that is
positioned on or attached on one edge of a bottom flange element;
however, other shapes can be used. One non-limiting function of the
stiffener elements is to provide the otherwise terminal edge of the
bottom flange element with a structure that can stiffen,
straighten, and/or strengthen the bottom flange element to resist
buckling, waving, and/or other stresses; however, this is not
required.
[0028] In still another and/or alternative aspect of the present
invention, there can optionally be provided a vertical strut that
can be positioned between two sub-structural wall construction
component. The vertical strut, when used, can facilitate in the
attachment of exterior cladding that may benefit from support along
the vertical edges of the cladding panel. The size, length, width,
shape and/or materials of the vertical strut are non-limiting. The
number of vertical struts positioned between the two spaced apart
sub-structural wall construction components and/or the spacing of
the vertical struts from one another is non-limiting. Generally,
the length of the vertical strut is the same or substantially the
same as the distance between the two spaced apart sub-structural
wall construction components such that each end contacts or is
positioned closely adjacent to a sub-structural wall construction
component; however, this is not required. Generally, each end of
the vertical strut is connected to a sub-structural wall
construction component; however, this is not required. The
connection arrangement is non-limiting (e.g., rivet, solder, weld
bead, adhesive, mechanical connection, bolt, screw, etc.). The top
surface of the vertical strut generally lies parallel to and/or in
the same plane as the top surface of the top flange element of the
sub-structural wall construction component when the sub-structural
wall construction component is connected to the building and the
vertical strut is connected to the building and/or the
sub-structural wall construction component; however, this is not
required. One or both ends of the vertical strut can be cut (e.g.,
miter cut) or otherwise shaped or formed such that they nest within
the space created by the two spaced apart sub-structural wall
construction components and to thereby facilitate in a flush
sub-structural framing arrangement; however, this is not
required.
[0029] In yet another and/or alternative aspect of the present
invention, there is provided a sub-structural wall construction
component that creates a ventilation and drainage airspace while
providing support for cladding materials. The sub-structural wall
construction component can be designed to adequately support a
wood, metal, clay, ceramic, cementitious, stone, or polymeric
exterior cladding system. The sub-structural wall construction
component can be designed to allow the exterior cladding system to
be supported some distance away from the drainage plane of the
building, thus creating an airspace between the exterior cladding
system and the drainage plane. The sub-structural wall construction
component can be designed to include punched and/or lanced openings
such that when the sub-structural wall construction component is
installed in a linear horizontal orientation, the sub-structural
wall construction component does not block or prohibit vertical air
circulation and/or water drainage. The sub-structural wall
construction component can be designed to include elements that are
articulated at some angle with respect to the horizontal plane so
as to promote drainage and discourage standing water accumulation
on any surface of the component. The sub-structural wall
construction component that does not necessarily interfere or
degrade upon the continuous exterior insulation of the building
except to the extent that prerequisite threaded fasteners pierce
the insulation so that the effective insulation value losses due to
"thermal bridging" are limited only to that of the threaded
fasteners. The sub-structural wall construction component
(optionally) incorporates preformed holes in one or more of the
flanges to facilitate the location and/or installation of
attachment fasteners.
[0030] It is one non-limiting object of the present invention to
provide a device that creates a ventilation and drainage airspace
while providing support for cladding materials.
[0031] It is another and/or alternative non-limiting object of the
present invention to provide a sub-structural wall construction
component that includes a) one or more bottom flange elements, b) a
top flange element, and c) one or more vented web elements.
[0032] It is still another and/or alternative non-limiting object
of the present invention to provide a sub-structural wall
construction component that adequately supports a wood, metal,
clay, ceramic, cementitious, stone, or polymeric exterior cladding
system.
[0033] It is yet another and/or alternative non-limiting object of
the present invention to provide a sub-structural wall construction
component that allows the exterior cladding system to be supported
some distance away from the drainage plane of the building, thus
creating an airspace between the exterior cladding system and the
drainage plane.
[0034] It is another and/or alternative non-limiting object of the
present invention to provide a sub-structural wall construction
component with punched and/or lanced openings such that when the
sub-structural wall construction component is installed in a linear
horizontal orientation, the sub-structural wall construction
component does not block or prohibit vertical air circulation
and/or water drainage.
[0035] It is still another and/or alternative non-limiting object
of the present invention to provide a sub-structural wall
construction component in which some of the elements (or segments)
of the sub-structural wall construction component are articulated
at some angle with respect to the horizontal plane so as to promote
drainage and discourage standing water accumulation on any surface
of the component.
[0036] It is yet another and/or alternative non-limiting object of
the present invention to provide a sub-structural wall construction
component that does not necessarily interfere or degrade upon the
continuous exterior insulation of the building except to the extent
that prerequisite threaded fasteners pierce the insulation so that
the effective insulation value losses due to "thermal bridging" are
limited only to that of the threaded fasteners.
[0037] It is still yet another and/or alternative non-limiting
object of the present invention to provide a sub-structural wall
construction component that (optionally) incorporates preformed
holes in one or more of the flanges to facilitate the location
and/or installation of attachment fasteners.
[0038] It is another and/or alternative non-limiting object of the
present invention to provide a vertical strut that can be
positioned between two sub-structural wall construction component
and wherein the vertical strut can facilitate the attachment of
exterior cladding that may benefit from support along the vertical
edges of the cladding panel.
[0039] It is still another and/or alternative non-limiting object
of the present invention to provide a vertical strut that can be
positioned between two sub-structural wall construction components
and wherein the vertical strut includes ends that can be miter cut
such that they nest within the space created by the two spaced
apart sub-structural wall construction components and thereby
facilitate in a flush sub-structural framing arrangement.
[0040] It is still another and/or alternative non-limiting object
of the present invention to provide a sub-structural wall
construction component that includes one or more stiffener elements
on one or more bottom flange elements.
[0041] These and other objects and advantages will become apparent
to those skilled in the art upon reading and following the
description taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Reference may now be made to the drawings which illustrate
various non-limiting embodiments that the invention may take in
physical form and in certain parts and arrangement of parts
wherein:
[0043] FIG. 1 is a is a cross-section view of an exterior cladding
system that includes the use of the sub-structural wall
construction component in accordance with the present
invention;
[0044] FIG. 2 is front view of the exterior cladding system of FIG.
1;
[0045] FIG. 3 is a front perspective view of two sub-structural
wall construction components and vertical strut positioned between
such sub-structural wall construction components which are mounted
to a building structure;
[0046] FIG. 4 is a front perspective view of one non-limiting
sub-structural wall construction component in accordance with the
present invention;
[0047] FIG. 5 is a cross-section view along line 5-5 of FIG. 4;
[0048] FIG. 6 is a top plan view of the sub-structural wall
construction component illustrated in FIG. 4;
[0049] FIGS. 7-10 is a front perspective view of several
sub-structural wall constructions that illustrate non-limiting
alternative opening configurations that can be used in the
sub-structural wall construction component;
[0050] FIGS. 11-16 illustrate cross-section views of non-limiting
alternate cross-sectional configurations of the sub-structural wall
construction component;
[0051] FIG. 17 is a front perspective view of one non-limiting
vertical strut in accordance with the present invention;
[0052] FIG. 18 is a side view of the vertical strut of FIG. 17;
and,
[0053] FIG. 19 is a cross-section view along line 19-19 of FIG.
17.
DETAILED DESCRIPTION OF THE NON-LIMITING EMBODIMENTS
[0054] Referring now to the drawings wherein the showings are for
the purpose of illustrating preferred embodiments of the invention
only and not for the purpose of limiting same, FIGS. 1-17
illustrate non-limiting configurations of a novel sub-structural
wall construction component 100 that can be used in combination
with a novel cladding system 20 in accordance with the present
invention. The sub-structural wall construction component 100 can
be used with a novel vertical strut 200; however, this is not
required. A non-limiting example of a vertical strut is illustrated
in FIGS. 1-3 and 17-20.
[0055] The sub-structural wall construction component 100 is
designed to create a ventilation and drainage airspace while
providing support for cladding materials. The sub-structural wall
construction component can be designed to adequately support a
wood, metal, clay, ceramic, cementitious, stone, or polymeric
exterior cladding system. The sub-structural wall construction
component can be designed to allow the exterior cladding materials
to be supported some distance away from the drainage plane of the
building, thus creating an airspace between the exterior cladding
system and the drainage plane. The sub-structural wall construction
component can be designed to include punched and/or lanced openings
such that when the sub-structural wall construction component is
installed in a linear horizontal orientation, the sub-structural
wall construction component does not block or prohibit vertical air
circulation and/or water drainage. The sub-structural wall
construction component can be designed to include elements that are
articulated at some angle with respect to the horizontal plane so
as to promote drainage and discourage standing water accumulation
on any surface of the component. The sub-structural wall
construction component can be designed so as to not necessarily
interfere or degrade upon the continuous exterior insulation of the
building except to the extent that prerequisite threaded fasteners
pierce the insulation so that the effective insulation value losses
due to "thermal bridging" are limited only to that of the threaded
fasteners.
[0056] Referring now to FIGS. 1-3, there is illustrated a
non-limiting cladding system 20 in accordance with the present
invention. The cladding system 20 is illustrated as connected to a
building or building structure 30 (e.g., outer wall surface, wall
studs, etc.). The material of the building to which the cladding
system is connected to is non-limiting (e.g., concrete, brick,
stone, wood, metal, plastic, fiberglass, etc.). For example, the
building structure could be an uninsulated stud wall.
[0057] Positioned on the outer surface of building or building
structure 30 is a wall sheathing board 40. The thickness and
material of the wall sheathing board are non-limiting. One
non-limiting wall sheathing board that can be used is a wood fibre
board that has a thickness of 0.5-1 inch. The wall sheathing board
is an optional component of the cladding system. The wall sheathing
board can be connected to, secured to, or otherwise maintained in
position relative to the outer surface of building or building
structure 30 by an adhesive, mechanical connector (e.g., nail,
screw, rivet, staple, bolt, hooks, hook and loop fastener, etc.),
etc. As illustrated in FIG. 1, a mechanical connector in the form
of a nail 50 is used to secure the wall sheathing board to the
outer surface of building or building structure.
[0058] Positioned on the outer surface of the wall sheathing board
40 is an air and/or water barrier 60. One non-limiting air and/or
water barrier is WEATHERGUARD.TM. by Commercial Innovations, Inc.
WEATHERGUARD.TM. is a water resistant, vapor permeable membrane. As
can be appreciated, the air and/or water barrier can be in the form
of a liquid material (e.g., liquid sealant, paint, etc.) that is
sprayed on, rolled or brushed on, or otherwise applied. The
material and thickness of the air and/or water barrier is
non-limiting. In one non-limiting configuration, the thickness of
the air and/or water barrier can be 0.01-0.2 inches. The air and/or
water barrier can be connected to, secured to, or otherwise
maintained in position relative to the wall sheathing board by an
adhesive, mechanical connector (e.g., nail, screw, rivet, staple,
bolt, hooks, hook and loop fastener, etc.), etc. As illustrated in
FIG. 1, a mechanical connector in the form of a nail 50 is used to
secure the air and/or water barrier to the wall sheathing board.
The use of the air and/or water barrier in the cladding system is
optional.
[0059] Positioned on the outer surface of the air and/or water
barrier 60 is insulation 70. The material (e.g., wool, styrofoam,
fiberglass, etc.) and thickness of the insulation is non-limiting.
One non-limiting insulation material is a rock wool insulation
having a thickness of about 0.5-10 inches. The insulation can be
connected to, secured to or other maintained in position relative
to the air and/or water barrier by an adhesive, mechanical
connector (e.g., nail, screw, rivet, staple, bolt, hooks, hook and
loop fastener, etc.), etc. As illustrated in FIG. 1, a mechanical
connector in the form of a nail 50 is used to secure the insulation
to the air and/or water barrier. The use of the insulation in the
cladding system is optional.
[0060] Positioned on the outer surface of the insulation 70 is
sub-structural wall construction component 100. As best illustrated
in FIGS. 4-16, the sub-structural wall construction component 100
includes first and second bottom flange elements 110, 120, a top
flange element 130, and first and second vented web elements 140,
150. The sub-structural wall construction component can be
partially or fully formed of a metal material (e.g., tin, stainless
steel, copper, steel, coated steel [galvanized, painted, etc.],
aluminum [painted or bare], bronze, zinc, or other metals or metal
alloys etc.); however, it can be appreciated that the
sub-structural wall construction component can be formed of other
or additional materials (e.g., composite materials, plastic, fiber
reinforced materials, etc.). The sub-structural wall construction
component can be formed of one or more pieces of material. As
illustrated in FIGS. 4-16, the sub-structural wall construction
component is formed of a single piece of material. The
sub-structural wall construction component can be formed by one or
more process (e.g., cold forming, hot forming, extruded, molded,
stamped, etc.). As illustrated in FIG. 6, the one piece
sub-structural wall construction component is illustrated in a
preformed state. The flat piece of material illustrated in FIG. 6
can be formed into the final shape of the sub-structural wall
construction component by folding, press brake, roll forming, or by
other means.
[0061] The top flange element 130 is generally a solid, un-punched
surface; however, the top flange element can include one or more
openings. The top flange element is generally a flat structure
wherein the top surface 132 generally lies in a single plane. The
top surface of the top flange element is generally oriented in the
vertical plane (plumb with respect to the ground). As illustrated
in FIG. 1, the top flange element functions as a mounting surface
for the exterior cladding material 80.
[0062] The first and second bottom flange elements 110, 120 are
designed to be secured to or connected to the outer surface of
building or building structure 30 and/or one or more other
structures of the cladding system. The first and second bottom
flange elements can be connected to, secured to, or otherwise
maintained in position relative to the outer surface of building or
building structure 30 and/or one or more other structures of the
cladding system by an adhesive, mechanical connector (e.g., nail,
screw, rivet, staple, bolt, hooks, hook and loop fastener, etc.),
etc. As illustrated in FIG. 1, a mechanical connector in the form
of a nail 50 is used to secure the first and second bottom flange
elements to insulation 70 and to ultimately connect the first and
second bottom flange elements to the building or building structure
30. A secondary fastener 90 (e.g., nail, screw, rivet, staple,
bolt, hooks, hook and loop fastener, etc.), can optionally be used
to secure the first and second bottom flange elements to insulation
70. As illustrated in FIG. 1, secondary fastener 90 in the form of
a screw is shorter than nail 50. Secondary fastener 90 is
illustrated as not contacting the building or building structure
30, thereby not forming a thermolink between the sub-structural
wall construction component and the building or building structure
30. Only nail 50 forms a thermolink between the sub-structural wall
construction component and the building or building structure 30.
The minimal thermo connection between the sub-structural wall
construction component and the building or building structure 30
formed by nail 50 minimizes thermo-insulation reduction of the
cladding system. The first and second bottom flange elements are
designed such that the top surface 112, 122 of the bottom flange
elements are located in a plane that is generally parallel to the
top surface 132 of the top flange element 130 as illustrated in
FIGS. 5 and 11-16. The first and second bottom flange elements can
optionally include openings 114, 124. The openings are generally
spaced from the edge of the first and second bottom flange
elements; however, this is not required. The openings are used to
facilitate in inserting fasteners 50 and/or 90 through the first
and second bottom flange elements when securing the sub-structural
wall construction component building or building structure 30
and/or insulation. When the openings are used, generally a
plurality of openings are positioned on each of the first and
second bottom flange elements. The openings on the first and second
bottom flange elements can be aligned with one another as
illustrated in FIG. 4; however, this is not required.
[0063] The first and second vented web elements 140, 150 are
secured to the top flange element 130 and the bottom flange
elements 110, 120. As illustrated in FIGS. 4 and 5, a first edge of
a first vented web element 140 is connected to a first edge of the
top flange element 130 and the second edge of the first vented web
element 140 is connected to a first edge of the first bottom flange
element 110. Also, a first edge of a second vented web 150 element
is connected to a second edge of the top flange element 130 and the
second edge of the second vented web element 150 is connected to a
first edge of the second bottom flange element 120. As illustrated
in FIG. 5, the top surface 142, 152 of the first and second vented
web elements lies in a plane that is non-parallel to the plane of
the top surface 132 of top flange element 130 and the top surface
112, 122 of the first and second bottom flange elements 110, 120.
The top surface 142, 152 of the first and second vented web
elements angles upwardly from the top surface 112, 122 of the first
and second bottom flange elements at an angle of a, b. Angles a and
b can be the same or different. Angles a and b are generally about
5.degree.-185.degree., typically 15.degree.-165.degree., more
typically about 30.degree.-150.degree. and, still more typically,
about 60.degree.-120.degree.. In one non-limiting arrangement
angles a and b are the same and are about 60.degree.-65.degree.. As
illustrated in FIGS. 3-5, 7-12 and 14-15, the two vented web
elements angle toward one another. However, as illustrated in FIG.
13, the two vented web elements are parallel to one another. As can
be appreciated, the two vented web elements can angle away from one
another. One purpose of the upward angle of the vented web elements
is that when the sub-structural wall construction component is
placed in non-vertical orientation (e.g., a horizontal orientation,
etc.) on a building structure, at least a portion or all of the
vented web element will not be aligned with a plane parallel to the
ground; thus, the sub-structural wall construction component will
promote drainage of liquid moisture and be less prone to
accumulation of moisture on any vented web element once the
sub-structural wall construction component is mounted to a building
structure.
[0064] Each of the vented web elements includes a plurality of
openings 144, 154. The openings in the vented web elements can be
formed by stamping or punching (a slug of metal material removed),
lanced (the metal material is pierced and displaced, but not
removed), and/or by some other or additional process. The size,
shape, orientation and/or number of openings in the vented web
elements are non-limiting. The orientation of the one or more
openings in the vented web elements is non-limiting. As illustrated
in FIG. 4, two rows of aligned openings having a generally
rectangular shape are illustrated. FIG. 7. illustrates two rows of
non-aligned openings having a generally elongated oval shape. FIG.
8 illustrates two rows of non-aligned openings having another
shape. FIG. 9 illustrates three rows of non-aligned openings having
a generally circular shape. FIG. 10 illustrates three rows of
aligned openings having a generally circular shape. As can be
appreciated, a plurality of different shaped openings can be used
on the one or both of the vented web elements. As also can be
appreciated, a single row of openings or more than three rows of
openings can be used on the one or both of the vented web elements.
As can also be appreciated, additional shapes of the openings can
be used on the one or both of the vented web elements. Generally,
the surface area of the openings on the vented web elements is less
than 70% of the total surface area of the top surface of the vented
web element, typically the surface area of the openings on the
vented web elements is less than 50% of the total surface area of
the top surface of the vented web element and, more typically, the
surface area of the openings on the vented web elements is less
than 40% of the total surface area of the top surface of the vented
web element.
[0065] Referring now to FIG. 5, the top surface 132 of the top
flange element 130 has a width f that is generally greater than a
width h of the top surface of the vented web elements 140, 150;
however, this is not required. The top surface 132 of the top
flange element 130 has a width f that is generally greater than a
width c of the top surface of the bottom flange elements 110, 120;
however, this is not required. The top surface 132 of the top
flange element 132 has a width f that is generally greater than a
combined a width (c+h) of the top surface 112, 124 of the bottom
flange elements 110, 120 and top surface 142, 152 of the vented web
elements 140, 150; however, this is not required. The top surface
112, 124 of the bottom flange elements 110, 120 has a width f that
is generally greater than a width h of the top surface of the
vented web elements 140, 150; however, this is not required.
[0066] The top surface 132 of the top flange element 130 is
elevated a distance e above the top surface 112, 124 of the bottom
flange elements 110, 120. Generally, the top surface of the top
flange element is elevated above the top surface of the bottom
flange elements at a distance of at least about 0.25 inches;
however, this is not required.
[0067] Referring now to FIGS. 12, 14 and 15, one or both of the
bottom flange elements 110, 120 can optionally include one or more
stiffener elements. The configuration of the one or more stiffener
elements, when used, is non-limiting. As illustrated in FIG. 12,
each of the bottom flange elements includes a stiffener element in
the form of a lip that angles upwardly from the top surface of the
stiffener elements. The upward angle of the stiffener element is
non-limiting. As illustrated in FIG. 12, the two lips are oriented
to be generally parallel to one another. As illustrated in FIG. 15,
the two lips are oriented to angle away from one another. As can be
appreciated, the two lips can be oriented to angle toward one
another. One function of the stiffener element is to provide the
otherwise terminal edge of the bottom flange element with a
structure that can stiffen, straighten, and/or strengthen the
bottom flange element to resist buckling, waving, and/or other
stresses.
[0068] Referring again to FIGS. 1-3, the sub-structural wall
construction component 100 is secured to the face of the insulation
70 by use of fasteners 50 and/or 90. The openings 114, 124 in
bottom flange elements 110, 120 can be for alignment and/or ease of
installing the fasteners. The top flange element 130 of the
sub-structural wall construction component is used as a mounting
surface for the exterior cladding material 80. Fasteners 82 are
used to secure the cladding material to the top flange element. The
type of fastener used is non-limiting. As illustrated in FIG. 1,
fastener 82 is in the form of a screw. Fastener 82 generally has a
length so as to not contact building or building structure 30. As
illustrated in FIG. 1, fastener 82 has a length so as to not
contact insulation 70. The manner in which the sheets of cladding
material are connected together is non-limiting. The top flange
element may optionally have punched holes for alignment and/or ease
of installing fasteners 82.
[0069] Referring now to FIGS. 103 and 17-19, vertical strut 200 can
optionally be positioned between two sub-structural wall
construction component. The vertical strut, when used, can
facilitate in the attachment of exterior cladding that may benefit
from support along the vertical edges of the cladding panel. The
size, length, width, shape and/or materials of the vertical strut
are non-limiting. The number of vertical struts positioned between
the two spaced apart sub-structural wall construction components
and/or the spacing of the vertical struts from one another are
non-limiting. As illustrated in FIGS. 1-3, the length of the
vertical strut is generally the same or substantially the same as
the distance between the two spaced apart sub-structural wall
construction components such that each end contacts or is
positioned closely adjacent to a sub-structural wall construction
component. The vertical strut includes first and second bottom
flanges 210, 220, a top flange 230, and first and second side
flanges 240, 250. The first and second bottom flanges 210, 220 can
optionally include openings 212, 222 to facilitate in inserting
fastener 90 through the first and second bottom flanges when
securing the vertical strut to the sub-structural wall construction
component. The top surface of the top flange 230 generally lies
parallel to and/or in the same plane as the top surface 132 of the
top flange element 130 of the sub-structural wall construction
component 100 when the sub-structural wall construction component
is connected to the insulation and the vertical strut is connected
to the sub-structural wall construction component; however, this is
not required. One or both ends of the vertical strut can be cut
(e.g., miter cut) or otherwise shaped or formed such that they nest
within the space created by the two spaced apart sub-structural
wall construction components and thereby facilitate in a flush
sub-structural framing arrangement as illustrated in FIGS. 1-3;
however, this is not required.
[0070] It will thus be seen that the objects set forth above, among
those made apparent from the preceding description, are efficiently
attained, and since certain changes may be made in the
constructions set forth without departing from the spirit and scope
of the invention, it is intended that all matter contained in the
above description and shown in the accompanying drawings shall be
interpreted as illustrative and not in a limiting sense. The
invention has been described with reference to preferred and
alternate embodiments. Modifications and alterations will become
apparent to those skilled in the art upon reading and understanding
the detailed discussion of the invention provided herein. This
invention is intended to include all such modifications and
alterations insofar as they come within the scope of the present
invention. It is also to be understood that the following claims
are intended to cover all of the generic and specific features of
the invention herein described and all statements of the scope of
the invention, which, as a matter of language, might be said to
fall therebetween.
* * * * *