U.S. patent application number 17/590055 was filed with the patent office on 2022-08-11 for cross laminated timber wall panel system.
This patent application is currently assigned to Mercer Mass Timber LLC. The applicant listed for this patent is Mercer Mass Timber LLC. Invention is credited to Daniel Delisle, Jeremy Thomas DeWitt, David P. Markman, Mark Mathey, Ondrei Stefan Poliak.
Application Number | 20220251836 17/590055 |
Document ID | / |
Family ID | |
Filed Date | 2022-08-11 |
United States Patent
Application |
20220251836 |
Kind Code |
A1 |
Mathey; Mark ; et
al. |
August 11, 2022 |
CROSS LAMINATED TIMBER WALL PANEL SYSTEM
Abstract
In one aspect, a wall panel is provided that includes a cross
laminated timber panel, a first extrusion, and a second extrusion.
The cross laminated timber panel includes a top side, a bottom
side, a first side, and a second side. The panel also includes a
notch in the bottom side and a T-flange on the top side. A wall
system is provided comprising a plurality of wall panels. A method
of installing the wall panel system is also provided.
Inventors: |
Mathey; Mark; (Seattle,
WA) ; DeWitt; Jeremy Thomas; (Redmomd, WA) ;
Poliak; Ondrei Stefan; (Cheney, WA) ; Markman; David
P.; (Oakland, CA) ; Delisle; Daniel; (Tousand
Oaks, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Mercer Mass Timber LLC |
Vancouver |
|
CA |
|
|
Assignee: |
Mercer Mass Timber LLC
Vancouver
CA
|
Appl. No.: |
17/590055 |
Filed: |
February 1, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16682104 |
Nov 13, 2019 |
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17590055 |
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International
Class: |
E04C 2/38 20060101
E04C002/38; E04B 2/72 20060101 E04B002/72; E04C 2/12 20060101
E04C002/12 |
Claims
1. A wall system comprising: at least four cross laminated timber
panels, each cross laminated timber panel including a top side, a
bottom side, a first side, a second side, a notch in the bottom
side, a T-flange on the top side, a first extrusion, and a second
extrusion; wherein the first extrusion and the second extrusion are
each a U-channel with an attached flange a first of the at least
four cross laminated timber panels including the first extrusion
attached to the first side and the second extrusion attached to the
top side; a second of the at least four cross laminated timber
panels including the first extrusion attached to the second side
and the second extrusion attached to the top side; a third of the
at least four cross laminated timber panels including the first
extrusion attached to the first side and the second extrusion
attached to the bottom side, and a fourth of the at least four
cross laminated timber panels including the first extrusion
attached to the second side and the second extrusion attached to
the bottoms side; the first extrusion of the first of the at least
four cross laminated timber panels mating with the first extrusion
of the second of the at least four cross laminates timber panels;
the first extrusion of the third of the at least four cross
laminated timber panels mating with the first extrusion of the
fourth of the at least four cross laminated timber panels; the
second extrusion of the third of the at least four cross laminated
timber panels mating with the second extrusion of the first of the
at least four cross laminated timber panels; the notch of the third
of the at least four cross laminated timber panels mating with the
T-flange of the first of the at least four cross laminated timber
panels; the second extrusion of the fourth of the at least four
cross laminated timber panels mating with the second extrusion of
the second of the at least four cross laminated timber panels; and
the notch of the fourth of the at least four cross laminated timber
panels mating with the T-flange of the second of the at least four
cross laminated timber panels.
2. The wall system of claim 1, wherein the U-channel includes a
seal.
3. A wall system comprising: at least four cross laminated timber
panels, each cross laminated timber panel including a top side, a
bottom side, a first side, a second side, a notch in the bottom
side, a T-flange on the top side, a first extrusion, and a second
extrusion; a first of the at least four cross laminated timber
panels including the first extrusion attached to the first side and
the second extrusion attached to the top side; a second of the at
least four cross laminated timber panels including the first
extrusion attached to the second side and the second extrusion
attached to the top side; a third of the at least four cross
laminated timber panels including the first extrusion attached to
the first side and the second extrusion attached to the bottom
side, and a fourth of the at least four cross laminated timber
panels including the first extrusion attached to the second side
and the second extrusion attached to the bottoms side; the first
extrusion of the first of the at least four cross laminated timber
panels mating with the first extrusion of the second of the at
least four cross laminated timber panels; the first extrusion of
the third of the at least four cross laminated timber panels mating
with the first extrusion of the fourth of the at least four cross
laminated timber panels; the second extrusion of the third of the
at least four cross laminated timber panels mating with the second
extrusion of the first of the at least four cross laminated timber
panels; the notch of the third of the at least four cross laminated
timber panels mating with the T-flange of the first of the at least
four cross laminated timber panels; the second extrusion of the
fourth of the at least four cross laminated timber panels mating
with the second extrusion of the second of the at least four cross
laminated timber panels; and the notch of the fourth of the at
least four cross laminated timber panels mating with the T-flange
of the second of the at least four cross laminated timber panels,
and a first continuous splice plate between the first extrusion of
the first of the at least four cross laminated timber panels and
the first extrusion of the second of the at least four cross
laminated timber panels; a second continuous splice plate between
the second extrusion of the first of the at least four cross
laminated timber panels and the second extrusion of the third of
the at least four cross laminated timber panels; a third continuous
splice plate between the second extrusion of the second of the at
least four cross laminated timber panels and the second extrusion
of the fourth of the at least four cross laminated timber panels;
and a fourth continuous splice plate between the first extrusion of
the third of the at least four cross laminated timber panels and
the first extrusion of the fourth of the at least four cross
laminated timber panels.
4. The wall system of claim 3 further including a patch plate at an
intersection of the at least four cross laminated timber
panels.
5. A method of installing a wall system comprising: providing at
least four wall panels, each wall panel including a cross laminated
timber panel including a top side, a bottom side, a first side, a
second side, a notch in the bottom side, a T-flange on the top
side, a first extrusion, and a second extrusion, wherein the first
extrusion and the second extrusion are each a U-channel with an
attachment flange, a first of the at least four cross laminated
timber panels including the first extrusion attached to the first
side and the second extrusion attached to the top side, a second of
the at least four cross laminated timber panels including the first
extrusion attached to the second side and the second extrusion
attached to the top side, a third of the at least four cross
laminated timber panels including the first extrusion attached to
the first side and the second extrusion attached to the bottom
side, and a fourth of the at least four cross aminated timber
panels including the first extrusion attached to the second side
and the second extrusion attached to the bottom side; installing
the first of the at least four cross laminated timber panels;
installing the second of the at least four cross laminated timber
panels adjacent to the first of the at least four cross laminated
timber panels by connecting the first extrusion of the second of
the at least four cross laminated timber panels mating with the
first extrusion of the first of the at least four cross laminated
timber panels; installing the third of the at least four cross
laminated timber panels on the first of the at least four cross
laminated timber panels by connecting the second extrusion of the
third of the at least four cross laminated timber panels with the
second extrusion of the first of the at least four cross laminated
timber panels and inserting the T-flange of the first of the at
least four cross laminated timber panels into the notch of the
third of the at least four cross laminated timber panels; and
installing the fourth of the at least four cross laminated timber
panels on the second of the at least four cross laminated timber
panels by connecting the second extrusion of the fourth of the at
least four cross laminated timber panels with the second extrusion
of the second of the at least four cross laminated timber panels,
inserting the T-flange of the second of the at least four cross
laminated timber panels into the notch of the fourth of the at
least four cross laminated timber panels, and connecting the first
extrusion of the fourth of the at least four cross laminated timber
panels.
6. The method of claim 5, wherein the U-channel includes a
seal.
7. A method of installing a wall system comprising: providing at
least four wall panels, each wall panel including a cross laminated
timber panel including a top side, a bottom side, a first side, a
second side, a notch in the bottom side, a T-flange on the top
side, a first extrusion, and a second extrusion, a first of the at
least four cross laminated timber panels including the first
extrusion attached to the first side and the second extrusion
attached to the top side, a second of the at least four cross
laminated timber panels including the first extrusion attached to
the second side and the second extrusion attached to the top side,
a third of the at least four cross laminated timber panels
including the first extrusion attached to the first side and the
second extrusion attached to the bottom side, and a fourth of the
at least four cross aminated timber panels including the first
extrusion attached to the second side and the second extrusion
attached to the bottom side; installing the first of the at least
four cross laminated timber panels; installing the second of the at
least four cross laminated timber panels adjacent to the first of
the at least four cross laminated timber panels by connecting the
first extrusion of the second of the at least four cross laminated
timber panels mating with the first extrusion of the first of the
at least four cross laminated timber panels; installing the third
of the at least four cross laminated timber panels on the first of
the at least four cross laminated timber panels by connecting the
second extrusion of the third of the at least four cross laminated
timber panels with the second extrusion of the first of the at
least four cross laminated timber panels and inserting the T-flange
of the first of the at least four cross laminated timber panels
into the notch of the third of the at least four cross laminated
timber panels; and installing the fourth of the at least four cross
laminated timber panels on the second of the at least four cross
laminated timber panels by connecting the second extrusion of the
fourth of the at least four cross laminated timber panels with the
second extrusion of the second of the at least four cross laminated
timber panels, inserting the T-flange of the second of the at least
four cross laminated timber panels into the notch of the fourth of
the at least four cross laminated timber panels, and connecting the
first extrusion of the fourth of the at least four cross laminated
timber panels; installing a second splice plate in the second
extrusion of the first of the at least four cross laminated timber
panels prior to installing the third of the at least four cross
laminated timber panels.
8. A method of installing a wall system comprising: providing at
least four wall panels, each wall panel including a cross laminated
timber panel including a top side, a bottom side, a first side, a
second side, a notch in the bottom side, a T-flange on the top
side, a first extrusion, and a second extrusion, a first of the at
least four cross laminated timber panels including the first
extrusion attached to the first side and the second extrusion
attached to the top side, a second of the at least four cross
laminated timber panels including the first extrusion attached to
the second side and the second extrusion attached to the top side,
a third of the at least four cross laminated timber panels
including the first extrusion attached to the first side and the
second extrusion attached to the bottom side, and a fourth of the
at least four cross aminated timber panels including the first
extrusion attached to the second side and the second extrusion
attached to the bottom side; installing the first of the at least
four cross laminated timber panels; installing the second of the at
least four cross laminated timber panels adjacent to the first of
the at least four cross laminated timber panels by connecting the
first extrusion of the second of the at least four cross laminated
timber panels mating with the first extrusion of the first of the
at least four cross laminated timber panels; installing the third
of the at least four cross laminated timber panels on the first of
the at least four cross laminated timber panels by connecting the
second extrusion of the third of the at least four cross laminated
timber panels with the second extrusion of the first of the at
least four cross laminated timber panels and inserting the T-flange
of the first of the at least four cross laminated timber panels
into the notch of the third of the at least four cross laminated
timber panels; and installing the fourth of the at least four cross
laminated timber panels on the second of the at least four cross
laminated timber panels by connecting the second extrusion of the
fourth of the at least four cross laminated timber panels with the
second extrusion of the second of the at least four cross laminated
timber panels, inserting the T-flange of the second of the at least
four cross laminated timber panels into the notch of the fourth of
the at least four cross laminated timber panels, and connecting the
first extrusion of the fourth of the at least four cross laminated
timber panels; installing a third splice plate in the second
extrusion of the second of the at least four cross laminated timber
panels prior to installing the fourth of the at least four cross
laminated timber panels.
9. A method of installing a wall system comprising: providing at
least four wall panels, each wall panel including a cross laminated
timber panel including a top side, a bottom side, a first side, a
second side, a notch in the bottom side, a T-flange on the top
side, a first extrusion, and a second extrusion, a first of the at
least four cross laminated timber panels including the first
extrusion attached to the first side and the second extrusion
attached to the top side, a second of the at least four cross
laminated timber panels including the first extrusion attached to
the second side and the second extrusion attached to the top side,
a third of the at least four cross laminated timber panels
including the first extrusion attached to the first side and the
second extrusion attached to the bottom side, and a fourth of the
at least four cross aminated timber panels including the first
extrusion attached to the second side and the second extrusion
attached to the bottom side; installing the first of the at least
four cross laminated timber panels; installing the second of the at
least four cross laminated timber panels adjacent to the first of
the at least four cross laminated timber panels by connecting the
first extrusion of the second of the at least four cross laminated
timber panels mating with the first extrusion of the first of the
at least four cross laminated timber panels; installing the third
of the at least four cross laminated timber panels on the first of
the at least four cross laminated timber panels by connecting the
second extrusion of the third of the at least four cross laminated
timber panels with the second extrusion of the first of the at
least four cross laminated timber panels and inserting the T-flange
of the first of the at least four cross laminated timber panels
into the notch of the third of the at least four cross laminated
timber panels; and installing the fourth of the at least four cross
laminated timber panels on the second of the at least four cross
laminated timber panels by connecting the second extrusion of the
fourth of the at least four cross laminated timber panels with the
second extrusion of the second of the at least four cross laminated
timber panels, inserting the T-flange of the second of the at least
four cross laminated timber panels into the notch of the fourth of
the at least four cross laminated timber panels, and connecting the
first extrusion of the fourth of the at least four cross laminated
timber panels; installing a fourth splice plate in the first
extrusion of the third of the at least four cross laminated timber
panels prior to installing the fourth of the at least four cross
laminated timber panels.
Description
FIELD OF INVENTION
[0001] The present invention relates generally to the art of
exterior walls of buildings, and more specifically to a wall panel,
a wall panel system, and a method of installation thereof, for
buildings.
BACKGROUND
[0002] Cross-Laminated Timber or CLT is a pre-fabricated,
engineered wood building material with unique and often superior
building, aesthetic, environmental, and cost attributes. CLT wood
panels are made by pressing perpendicular layers of lumber together
with a layer of formaldehyde-free adhesive. The fusion of
orthogonal wood layers is what gives CLT biaxial strength,
durability, and stability. CLT can serve as a system-based approach
for floors, walls, and roofs to form a high-performance,
sustainable, and beautiful mass timber building of virtually any
type.
[0003] CLT requires less energy to produce than other building
materials such as steel and concrete and is made from renewable
material. CLT panels may be prefabricated and are also lighter than
panels made from other material such as steel, thereby reducing
design costs of the building. CLT panels may be connected together
to create the floor, wall, or roof.
[0004] Most wall panels of a curtain wall system are constructed
from glass and aluminum. Not only are these materials expensive,
they limit the design of the wall panel, and thus, the wall
system.
SUMMARY
[0005] In one aspect, a wall panel is provided that includes an
infill component, a first extrusion, and a second extrusion. The
infill component includes a top side, a bottom side, a first side,
and a second side. The panel also includes a notch in the bottom
side and a T-flange on the top side. A wall system is provided
comprising a plurality of connected wall panels. A method of
installing the wall panel system is also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The foregoing summary, as well as the following detailed
description will be better understood when read in conjunction with
the appended drawings. For the purpose of illustration, there is
shown in the drawings different embodiments. It should be
understood, however, that the teachings are not limited to the
precise wall panel system arrangement shown.
[0007] FIG. 1 is a front, left perspective view of a first
embodiment of a wall panel.
[0008] FIG. 2 is an exploded view of an infill component.
[0009] FIG. 3 is a front, left perspective view of a second wall
panel installed with a first wall panel.
[0010] FIG. 4 is a front, left perspective view of a third wall
panel installed with the first wall panel and the second wall panel
of FIG. 3.
[0011] FIG. 5 is a front, left perspective view of a fourth wall
panel installed with the first wall panel, the second wall panel,
and the third wall panel of FIG. 4.
[0012] FIG. 6 is a front, left perspective view of the intersection
of the wall panel system showing the seals, continuous splice
plates, and the patch plate.
[0013] FIG. 7 is a first cross-section view of adjacent wall panels
of the wall panel system.
[0014] FIG. 8 is a second cross-section view of adjacent wall
panels of the wall panel system.
[0015] FIG. 9 is a third cross-section view of adjacent wall panels
of the wall panel system.
[0016] FIG. 10 is a first cross-section view of stacked wall panels
of the wall panel system.
[0017] FIG. 11 is a second cross-section view of stacked wall
panels of the wall panel system.
[0018] FIG. 12 is a third cross-section view of stacked wall panels
of the wall panel system.
[0019] FIG. 13 is a flow chart of a method of installing the wall
panel system.
DETAILED DESCRIPTION
[0020] A wall panel is provided that comprises a cross laminated
timber panel. The cross laminated timber panel allows various
materials and components to be added to the wall panel which
provides flexibility of the wall panel design as well as the design
of the wall system. The wall panel includes an infill component
which includes a CLT panel. The wall panel also includes a first
extrusion and a second extrusion. The panel also includes a notch
in the bottom side and a T-flange on the top side. The extrusions,
the notch, and the T-flange allow the wall panel to easily and
efficiently connect to other wall panels. A plurality of wall
panels can connect together to create a wall system.
[0021] FIG. 1 is a front, left perspective view of a first
embodiment of a wall panel 100. The wall panel 100 may be load
bearing and may be non-load bearing. The wall panel 100 comprises
an infill component 200. The infill component 200 includes a top
side 310, a bottom side 320, a first side 330, and a second side
340 (not visible in FIG. 1). Moreover, the infill component 200
includes a notch 400 in the bottom side 320 and a T-flange 500 on
the top side 310. The wall panel 100 also includes a first
extrusion 600a and a second extrusion 600b.
[0022] As shown in FIG. 1, the first extrusion 600a is attached to
the second side 340 and the second extrusion 600b is attached to
the top side 310. Alternatively, the first extrusion 600a may be
attached to the first side 330 and the second extrusion 600b
attached to the top side 310; the first extrusion 600a may be
attached to a first side 330 and the second extrusion 600b attached
to the bottom side 320; or the first extrusion 600a may be attached
to a second side 340 and the second extrusion 600b attached to the
bottom side 320.
[0023] The wall panel 100 may also include a third extrusion and a
fourth extrusion (not shown). In this embodiment, the first
extrusion 600a is attached to the first side 330, the second
extrusion 600b is attached to the top side 310, the third extrusion
is attached to the second side 340, and the fourth extrusion is
attached to the bottom side 320.
[0024] Each extrusion 600a, 600b may comprise a U-channel with an
attachment flange, as shown in FIG. 1. Alternatively, the
extrusions 600a, 600b may comprise two or more connected angles.
The U-channel may also include seals or gaskets 610, continuous
splice plates 620, and closed cell foam (not shown). The seals or
gaskets 610 may be silicone gaskets, and the splice plates 620 may
be aluminum. The extrusions 600a, 600b and T-flange 500 may be
galvanized steel, aluminum, vinyl, or other suitable rigid
material. The extrusions 600a, 600b, the T-flange 500, and the
notch 400 allow the wall panel 100 to connect with adjacent wall
panels 100. The extrusions 600a, 600b connect with the extrusions
of an adjacent wall panel 100. The T-flange 500 connects with the
notch 400 of an adjacent wall panel 100. The notch 400 connects
with the T-flange 500 of an adjacent wall panel 100.
[0025] FIG. 2 is an exploded view of an infill component 200.
Referring to FIG. 2, the infill component 200 includes a cross
laminated timber panel 210. The cross laminated timber panel 210
may include a vapor barrier adhered to the surface to prevent water
vapor from diffusing into the cross laminated timber panel 210. The
infill component 200 may also include insulation 220. The
insulation may include two layers of mineral wool. The infill
component 200 may also include a terra cotta panel 250. The terra
cotta panel 250 may be combined with other materials and may be
customized to create a variety of exterior designs of buildings.
The terra cotta panel 250 is connected to the insulation 220 and
cross laminated timber panel 210 via hat channels 230 and
horizontal supports with terra cotta clips 240. The cross laminated
timber panel 210 may also include window flashing 260, metal panels
270, windows 280, and an aluminum extrusion 290, as shown in FIG.
2. The aluminum extrusion 290 protects the end-grain.
[0026] A plurality of connected wall panels 100 makes up a wall
panel system 700. The wall panels 100 mate with adjacent wall
panels 100. Each wall panel 100 of the wall panel system 700
includes the features, components, and embodiments of a wall panel
100 previously discussed in detail. The wall panel system 700
includes at least two connected wall panels 100. The wall panels
100 connect via the first extrusions 600a or the second extrusions
600b, T-flange 500 and notch 400.
[0027] FIG. 3 is a front, left perspective view of a second wall
panel 100b installed with a first wall panel 100a. As shown in FIG.
3, a first wall panel 100a adjacently mates with a second wall
panel 100b. The first wall panel 100a mates with the second wall
panel 100b via the first extrusion 600a of the first wall panel
100a and the first extrusion 600a of the second wall panel 100b. A
splice plate 620 extends between the first extrusion 600a of the
first wall panel 100a and the first extrusion 600a of the second
wall panel 100b (not visible in FIG. 3). A splice plate 620 may
also be inserted in the second extrusion 600b of the first wall
panel 100a and the second extrusion 600b of the second wall panel
100a to connect to a second extrusion 600b of a third wall panel
100c and a second extrusion 600b of a fourth wall panel 100d
respectively. The connections to the third wall panel 100c and the
fourth wall panel 100d are discussed in further detail below and
shown in FIGS. 4 and 5. The wall panel system 700 may also include
a patch plate 630 to weatherproof the joint between the first wall
panel 100a and the second wall panel 100b. Preferably, the patch
plate 630 is an extruded aluminum patch plate.
[0028] FIG. 4 is a front, left perspective view of a third wall
panel 100c installed with the first wall panel 100a and the second
wall panel 100b of FIG. 3. Referring to FIG. 4, the wall panel
system 700 may also include a third wall panel 100c stacked on the
first wall panel 100a. The notch 400 of the third wall panel 100c
mates with the T-flange 500 of the first wall panel 100a. Moreover,
the second extrusion 600b of the third wall panel 100c mates with
the second extrusion 600b of the first wall panel 100a. The splice
plate 620 in the second extrusion 600b of the first wall panel
100a, previously shown in FIG. 3, extends between the second
extrusion 600b of the first wall panel 100a and the second
extrusion 600b of the third wall panel 100c (not visible in FIG.
4). A splice plate 620 may also be inserted in the first extrusion
600a of the third wall panel 100c to connect with the first
extrusion 600a of the fourth wall panel 100d.
[0029] FIG. 5 is a front, left perspective view of a fourth wall
panel 100d installed with the first wall panel 100a, the second
wall panel 100b, and the third wall panel 100c of FIG. 4. As shown
in FIG. 5, the wall panel system 700 may include a fourth wall
panel 100d. The fourth wall panel 100d connects with the second
wall panel 100b and the third wall panel 100c. The T-flange 500 of
the second wall panel 100b mates with the notch 400 of the fourth
wall panel 100d. Moreover, the second extrusion 600b of the second
wall panel 100b mates with the second extrusion 600b of the fourth
wall panel 100d, and the first extrusion 600a of the fourth wall
panel 100d mates with the first extrusion 600a of the third wall
panel 100c. As shown in FIG. 5, a splice plate 620 extends between
the second extrusion 600b of the second wall panel 100b and the
second extrusion 600b of the fourth wall panel 100d. A splice plate
620 also extends between the first extrusion 600a of the third wall
panel 100c and the first extrusion 600a of the fourth wall panel
100d.
[0030] Mating the extrusions 600a, 600b of the four wall panels
100a-d forms a joint or intersection in the shape of a "cruciform"
or"+" sign. FIG. 6 is a front, left perspective view of the
intersection of the wall panel system 700 showing the seals or
gaskets 610, continuous splice plates 620, and the patch plate 630.
FIG. 6 shows the seals or gaskets 610, splice plates 620, and patch
plate 630 of the "cruciform." The seals or gaskets 610, the splice
plates 620, and the patch plate 630 weatherproof the "cruciform"
or"+" sign joint of the wall panel system 700.
[0031] Although an example four wall panel 100a-d wall panel system
700 is illustrated, the wall panel system 700 may include
additional wall panels 100. The notches 400 and second extrusion
600b of any additional rows of wall panels 100 mate with the
T-flange 500 and second extrusion 600b of the previous row of wall
panels 100. Moreover, the first extrusions 600a of any additional
adjacent wall panels 100 mate with the first extrusions 600a of the
previous adjacent wall panels 100.
[0032] FIG. 7 is a first cross-section view of adjacent wall panels
100 of the wall panel system 700. FIG. 7 depicts the vertical mated
joint between adjacent wall panels 100. The first extrusions 600a
are connected to the wall panels 100. The first extrusions 600a may
be screwed into the wall panel 100, adhered to the wall panel 100,
or otherwise connected. The U-channel may be connected to the
attachment flange via staggered fasteners. The U-channel and
attachment flange joint may be sealed with silicone to prevent
water from entering the joint. The first extrusions 600a may
include open cell foam to act as a thermal break or thermal
barrier. The splice plate 620 may slide between the seals or
gaskets 610 to allow for different distances between adjacent wall
panels 100 and to allow expansion and contraction of the wall
panels 100. The ends of the splice plate 620 may be thicker to
prevent the splice plate 620 from slipping through the seals or
gaskets 610 and becoming disengaged from the first extrusions 600a.
FIG. 7 shows an undisplaced position of adjacent wall panels 100.
The distance between adjacent wall panels 100 at this position may
be approximately 1.5''.
[0033] As further illustrated in FIGS. 8 and 9, the first
extrusions 600a and splice plate 620 connection permits a varying
degree of displacement between adjacent wall panels 100. FIG. 8
depicts adjacent wall panels 100 with minimal displacement. While,
FIG. 9 depicts adjacent wall panels 100 at the maximum
displacement.
[0034] FIG. 8 is a second cross-section view of adjacent wall
panels 100 of the wall panel system 700. FIG. 8 shows the wall
panels 100 and joint of FIG. 7. However, FIG. 8 depicts the
adjacent wall panels 100 in a closer or closed position. The ends
of the splice plate 620 are touching the backs of the U-shape
channel of the extrusions 600a. At this position, the adjacent wall
panels 100 are the closest together representing a minimum joint
dimension. The distance between adjacent wall panels 100 at this
position may be approximately 0.29''.
[0035] FIG. 9 is a third cross-section view of adjacent wall panels
100 of the wall panel system 700. FIG. 9 shows the wall panels 100
and joint of FIG. 7 and FIG. 8. However, FIG. 9 depicts the
adjacent wall panels 100 in a farther or open position. The ends of
the splice plate 620 are against the seals or gaskets 610. At this
position, the adjacent wall panels 100 are the farthest apart
representing a maximum joint dimension. The distance between
adjacent wall panels 100 at this position may be approximately
2.332''.
[0036] FIG. 10 is a first cross-section view of stacked wall panels
100 of the wall panel system. FIG. 10 depicts a cross-section view
of the mated horizontal joint between stacked wall panels 100. The
second extrusions 600b may be screwed into the wall panel 100,
adhered to the wall panel 100, or otherwise connected. The
U-channel may be connected to the attachment flange via staggered
fasteners. The U-channel and attachment flange joint may be sealed
with silicone to prevent water from entering the joint. The second
extrusions 600b may include open cell foam to act as a thermal
break or thermal barrier. The splice plate 620 may slide between
the seals or gaskets 610 to allow for different distances between
stacked wall panels 100 and to allow expansion and contraction of
the wall panels 100. The ends of the splice plate 620 may be
thicker to prevent the splice plate 620 from slipping through the
seals or gaskets 610 and becoming disengaged from the second
extrusions 600b. FIG. 10 shows an undisplaced position of stacked
wall panels 100. The distance between stacked wall panels 100 at
this position may be approximately 0.65''.
[0037] As further illustrated in FIGS. 11 and 12, the second
extrusions 600b and splice plate 620 connection and the T-flange
500 and notch 400 connection permits a varying degree of
displacement between stacked wall panels 100. FIG. 11 depicts
stacked wall panels 100 with minimal displacement. While, FIG. 12
depicts stacked wall panels 100 at a greater displacement.
[0038] FIG. 11 is a second cross-section view of stacked wall
panels 100 of the wall panel system 700. FIG. 11 shows the wall
panels 100 and horizontal joint of FIG. 10. However, FIG. 11
depicts the stacked wall panels 100 in a closer or closed position.
The ends of the splice plate 620 are slid further into the
U-channels of the second extrusions 600b. The T-flange 500 is also
further inserted in the notch 400 of the stacked wall panel 100. At
this position, the stacked wall panels 100 are the closest together
representing a minimum joint dimension. The distance between
stacked wall panels 100 at this position may be approximately
0.312''.
[0039] FIG. 12 is a third cross-section view of stacked wall panels
100 of the wall panel system 700. FIG. 12 shows the same wall
panels 100 and horizontal joint of FIG. 10 and FIG. 11. However,
FIG. 12 depicts the stacked wall panels 100 in a farther or open
position. The ends of the splice plate 620 are close to the seals
or gaskets 610. Additionally, the T-flange 500 is closer to the
opening of the notch 400 in the open position. At this position,
the stacked wall panels 100 are the farthest apart representing a
maximum joint dimension. The distance between stacked wall panels
100 at this position may be approximately 0.988''.
[0040] FIG. 13 is a flow chart of a method 1300 of installing the
wall panel system. The method of installing an example four wall
panel 100a-d wall panel system 700 can be carried out according to
the method 1300 described in FIG. 13 and described below.
[0041] In step 1310, the components of a wall panel system 700, as
described above, are received. In step 1320, the first wall panel
is installed. In step 1340, the second wall panel 100b is placed
adjacent to the first wall panel 100a by mating the first extrusion
600a of the second wall panel 100b with the first extrusion 600a of
the first wall panel 100a. In step 1380, the third wall panel 100c
is stacked on the first wall panel 100a by mating the notch 400 and
second extrusion 600b of the third wall panel 100c with the
T-flange 500 and second extrusion 600b of the first wall panel 100a
respectively. In step 1400, the fourth wall panel 100d is stacked
on the second wall panel 100b by mating the notch 400 and second
extrusion 600b of the fourth wall panel 100d with the T-flange 500
and second extrusion 600b of the second wall panel 100b
respectively. The fourth wall panel 100d is also adjacently
connected to the third wall panel 100c by mating the first
extrusion 600a of the fourth wall panel 100d with the first
extrusion 600a of the third wall panel 100c.
[0042] The method 1300 may also include step 1330 of installing a
first splice plate 620 in the first extrusion 600a of the first
wall panel 100a prior to placing the second wall panel 100b.
[0043] The method 1300 may also include step 1350 of installing a
second splice plate 620 in the second extrusion 600b of the first
wall panel 100a prior to stacking the third wall panel 100c.
[0044] The method 1300 may also include step 1360 of installing a
third splice plate 620 in the second extrusion 600b of the second
wall panel 100b prior to stacking the third wall panel 100c and the
fourth wall panel 100d.
[0045] The method 1300 may also include step 1370 of installing a
patch plate 630 at the intersection of the first splice plate 620,
the second splice plate 620, and the third splice plate 620 prior
to stacking the third wall panel 100c.
[0046] The method 1300 may also include step 1390 of installing a
fourth splice plate 620 in the first extrusion 600a of the third
wall panel 100c prior to stacking the fourth wall panel 100d.
[0047] Having thus described in detail a preferred selection of
embodiments of the present invention, it is to be appreciated and
will be apparent to those skilled in the art that many physical
changes could be made to the wall panel, the wall panel system, and
the installation thereof, without altering the inventive concepts
and principles embodied therein. The present embodiments are
therefore to be considered in all respects as illustrative and not
restrictive, the scope of the invention being indicated by the
appended claims rather than by the foregoing description, and all
changes which come within the meaning and range of equivalency of
the claims are therefore to be embraced therein.
* * * * *