BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed toward composite wall panel systems and, more particularly, towards drained and back ventilated composite wall panel systems.
2. Description of Related Art
Thin composite architectural wall panels are generally manufactured by laminating metal skins to a plastic core. These sheets are typically shipped to a fabricator where they are cut to size and routed so as to return the edges around the perimeter. Typically, extrusions are fabricated and applied to the panel perimeter to create panel joinery. Also, stiffeners are typically applied in the field of the panel, i.e., the major flattened portion, to reduce the bowing of the thin panel under load. The terms “thin composite panel” and “thin composite architectural panel” generally relate to a genre of architectural panels, configured substantially as described above, where a thickness dimension as measured between opposing faces in the field of the panel can generally be between about 4 mm and about 8 mm, though a greater range of thicknesses, such as less than about 15 mm or less than about 10 mm are also utilized.
Referring to FIG. 1, upper and lower panels 1, 2 each include an extrusion 4 at the panel perimeter, as discussed above, at a horizontal joint 5 defined between the panels 1, 2. The extrusions 4 define a recess 6 to receive a spline 7. Typically, the extrusions 4 are fabricated and applied to the perimeter of the panels 1, 2, as noted above. The extrusions 4 are generally mitered at the corners to create the panel joinery around the panel perimeter. At the horizontal joint 5, the recess 6 may become a water trap and channel water to an interior side 8 of the panels 1, 2.
SUMMARY OF THE INVENTION
A wall panel includes a panel body, a first jamb clip, a second jamb clip, a bottom member, and an attachment clip. The first jamb clip is positioned adjacent to a right side of the panel body and the second jamb clip is positioned adjacent to a left side of the panel body. The first and second jamb clips are configured to receive a portion of a spline. The bottom member has an engagement portion and is positioned adjacent to a bottom end of the panel body. The attachment clip is positioned adjacent to an upper end of the panel body and has an engagement receiving portion configured to engage an engagement portion of an adjacent panel. The bottom end of the panel body is configured to define a ventilation gap when joined to an adjacent panel.
The engagement portion of the bottom member may extend upward, and the engagement receiving portion of the attachment clip may comprise a downwardly opening channel. The engagement portion of the bottom member may also extend downward, and the engagement receiving portion of the attachment clip may comprise an upwardly opening channel. The wall panel may also include a rail member positioned adjacent to an upper end of the panel body with the panel body positioned between the attachment clip and the rail member. The rail member may have an extension that extends outward and the rail member and the attachment clip may have cooperating engagement member. The wall panel may include a stiffener secured to the panel body and the stiffener may be secured to the bottom member via a stiffener clip. The stiffener clip may have an extension extending downward and the extension may engage a stiffener receiving portion of the bottom member. An upper portion of the stiffener clip may be secured to the stiffener via a fastener. The stiffener may extend along a longitudinal direction of the panel body. The upper end of the panel may include a return portion configured to define a horizontal drain shelf. The return portion of the upper end of the panel may be L-shaped in cross-section.
In another embodiment, a wall panel system includes a first panel having a bottom member positioned adjacent to a bottom end of the first panel, and a second panel positioned adjacent to the first panel and defining a horizontal joint. The second panel has an attachment clip positioned adjacent to an upper end of the second panel. The attachment clip engages the bottom member, and the bottom end of the first panel and the upper end of the second panel define a ventilation gap.
The second panel may have a rail member positioned adjacent to the upper end of the second panel with the rail member having an extension that extends outward and the extension defining an upper end of the ventilation gap and configured to deflect fluid entering the horizontal joint. The rail member and the attachment clip may each have an engagement member with the engagement members of the rail member and the attachment clip being engaged with each other. The bottom member may have an engagement portion and the attachment clip may have an engagement receiving portion with the engagement portion of the bottom member engaging the engagement receiving member of the attachment clip. The first panel may have a jamb clip positioned adjacent to a right side of the first panel with the jamb clip configured to receive a portion of a spline. The wall panel system may further include a third panel positioned adjacent to the first panel and defining a vertical joint. The first panel and the third panel may each have a jamb clip positioned adjacent to the vertical joint with the respective jamb clips of the first and third panels defining a receptor. The wall panel system may also include a spline received by the receptor.
In a further embodiment, a wall panel system includes a panel having a first jamb clip positioned adjacent to a right side of the panel, a second jamb clip positioned adjacent to a left side of the panel, a bottom member positioned adjacent to a bottom end of the panel and between the first and second jamb clips, an attachment clip positioned adjacent to an upper end of the panel, and a stiffener extending along a longitudinal direction of the panel body. The wall panel system also includes a support and a stiffener clip having a stiffener receiving portion. The stiffener clip is secured to the support and the stiffener receiving portion engages the stiffener. The stiffener may be positioned at about a midpoint of a short dimension of the panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a conventional thin composite wall cladding system at a horizontal joint;
FIG. 2 is a sectional view of a wall panel system at a horizontal joint according to one embodiment of the present invention;
FIG. 3 is a sectional view of the wall panel system shown in FIG. 2, showing the wall panel system between attachment clips;
FIG. 4 is a sectional view of a of a wall panel system at a horizontal joint according to a further embodiment of the present invention;
FIG. 5 is a sectional view of the wall panel system shown in FIG. 4, showing the wall panel system between attachment clips;
FIG. 6 is a sectional view of a wall panel system at a vertical joint according to one embodiment of the present invention;
FIG. 7 is a sectional view of wall panel system at a vertical joint according to a further embodiment of the present invention;
FIG. 8 is a sectional view of a wall panel system at a vertical joint according to another embodiment of the present invention;
FIG. 9 is an elevational view of a wall panel system according to one embodiment, showing wall panels in an installed position;
FIG. 10 is a sectional view of the wall panel systems shown in FIGS. 2 and 4, showing a vertical spline at a horizontal joint;
FIG. 11 is a sectional view taken along the line X-X in FIG. 10;
FIG. 12 is a schematic elevational view of a wall panel system according to one embodiment, showing placement of stiffener clips; and
FIG. 13 is a sectional view taken along the line XII-XII in FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described with reference to the accompanying figures. For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom” and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is to be understood that the specific apparatus illustrated in the attached figures and described in the following specification is simply an exemplary embodiment of the present invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.
Referring to FIGS. 2 and 3, a wall panel system 10 according to one embodiment includes upper and lower panels 12, 14 secured to a support 16, such as a sub-frame, and defining a horizontal joint 18. The panels 12, 14 each have a generally rectangular (or square) panel body formed by laminating metal skins to a plastic core, although other panel configurations may be utilized. The sub-frame is typically secured to a structural framing member, such as a stud, with a thermal, vapor, and air and water barrier positioned between the structural framing and the sub-frame. The supports 16 are typically spaced apart along a building structure (not shown). The upper panel 12 includes a bottom member 20 that extends along a bottom end 22 of the upper panel 12. The bottom member 20 is a continuous extrusion that includes an engagement portion 24 and a pair of stiffener receiving portions 26. The bottom member 20 is secured to the upper panel 12 via a fastener 28, such as a screw or rivet, that extends through the bottom member 20 and a return portion 30 of the upper panel 12. The lower panel 14 includes a rail 32 that extends along an upper end 34 of the lower panel 14. The rail 32 is a continuous extrusion generally having a Z-shape and defining an upper extension 36, an engagement portion 38, and a lower leg portion 40. The lower panel 14 is secured to the support 16 via an attachment clip 42. In particular, a fastener 44 extends through the attachment clip 42, through a return portion 46 of the lower panel 14, through the rail 32 and into the support 16.
The attachment clip 42 is positioned between the bottom member 20 and the rail 32 at the support 16. The return portion 46 of the panel 14 is positioned between the attachment clip 42 and the rail 32. The attachment clip 42 includes an upper engagement member 48 and an engagement receiving portion 50. The upper engagement member 48 of the attachment clip 42 is received by the engagement portion 38 of the rail 32 and the engagement portion 24 of the bottom member 20 is received by the engagement receiving portion 50. In particular, the engagement portion 24 of the bottom member 20 extends generally upward to be received and engaged by the engagement receiving portion 50 of the attachment clip 42 thereby securing the upper panel 12 to the attachment clip 42. The engagement receiving portion 50 is a channel that opens downward and includes a ledge for engaging the engagement portion 24. The engagement portion 24 and the engagement receiving portion 50 may be secured to each other through cooperating structure, such as through a friction fit arrangement, detent arrangement, or any other suitable arrangement.
Referring again to FIG. 2, the upper panel 12 may include a stiffener 52 that is secured to the upper panel 12 via a stiffener clip 54 having an upper portion 56 and a lower portion 58 with a pair of extensions 60. The stiffener clip 54 is secured to the stiffener 52 via a fastener 62, such as a screw, extending through the upper portion 56 of the stiffener clip 54 and into the stiffener 52. The pair of extensions 60 of the stiffener clip 54 is received by the stiffener receiving portions 26 of the bottom member 20. The pair of extensions 60 of the stiffener clip 54 and the stiffener receiving portions 26 of the bottom member 20 engage each other through cooperating structure, such as through a friction fit arrangement, detent arrangement, or any other suitable arrangement. The lower panel 14 may also include a stiffener 64 that is secured to the rail 32 of the lower panel 14 via a fastener 66, such as a screw, extending through the lower leg portion 40 of the rail 32 and into the stiffener 64.
The return portion 46 of the upper end 34 of the lower panel 14 is generally L-shaped and defines a horizontal water shedding drain shelf. Further, the upper end 34 of the panel 14 and the rail 32 generally define a Z-shape at the horizontal joint 18. Water that may enter the horizontal joint 18 will contact the horizontal drain shelf and will be directed back out of the horizontal joint 18. As discussed above, the lower panel 14 is positively fastened to the support 16 and captures the lower panel 14 and the rail 32 such that wall panel system 10 does not have to solely rely upon adhesives to hold the panel 14 onto the rail 32. Further, as shown more clearly in FIG. 3, the upper extension 36 of the rail 32 and the bottom member 20 define a ventilation gap 68 without allowing a substantial amount of water penetration through the gap 68. In particular, the upper extension 36 of the rail 32 is configured to deflect fluid and keep wind blown water to the exterior and out of the panel cavity, i.e., between the wall panel system and the air and water barrier behind the panels. As shown in FIG. 2, a screen 70 may be positioned between the upper extension 36 of the rail 32 and the bottom member 20 to prevent bugs from passing through this area. Further, as shown in FIG. 3, the upper and lower panels 12, 14 define a space 69 behind the rail 32 between attachments to the support 16 for back ventilation.
Referring to FIGS. 4 and 5, a wall panel system 110 according to a further embodiment is disclosed. The wall panel system 110 shown in FIGS. 4 and 5 is similar to the wall panel system 10 described above. The wall panel system 110 includes upper and lower panels 112, 114 secured to a support 116 and defining a horizontal joint 118. The panels 112, 114 each have a generally rectangular (or square) panel body formed by laminating metal skins to a plastic core, although other panel configurations may be utilized. The upper panel 112 includes a bottom member 120 that extends along a bottom end 122 of the upper panel 112. The bottom member 120 is a continuous extrusion that includes an engagement portion 124 and a pair of stiffener receiving portions 126. The bottom member 120 is secured to the upper panel 112 via a fastener 128, such as a screw, that extends through the bottom member 120 and a return portion 130 of the upper panel 112. The lower panel 114 includes a rail 132 that extends along an upper end 134 of the lower panel 114. The rail 132 is a continuous extrusion generally having a Z-shape and defining an upper extension 136, an engagement portion 138, and a lower leg portion 140.
The lower panel 114 is secured to the support 116 via an attachment clip 142. In particular, a fastener 144 extends through the attachment clip 142, through a return portion 146 of the lower panel 114, through the rail 132 and into the support 116. The attachment clip 142 is positioned between the bottom member 120 and the rail 132 at the support 116. The attachment clip 142 includes an upper engagement portion 148 and an engagement receiving portion 150. The upper engagement portion 148 of the attachment clip 142 is received by the engagement portion 138 of the rail 132 and the engagement portion 124 of the bottom member 120 is received by the engagement receiving portion 150. In particular, the engagement portion 124 of the bottom member 120 extends generally downward to be received and engaged by the engagement receiving portion 150 of the attachment clip 142. The engagement receiving portion 150 is a channel that opens upward and includes a ledge for engaging the engagement portion 124. The engagement portion 124 and the engagement receiving portion 150 may be secured to each other through cooperating structure, such as through a friction fit arrangement, detent arrangement, or any other suitable arrangement. Accordingly, the upper panel 112 may be dropped into place with the engagement portion 124 of the bottom member 120 being received and engaged by the engagement receiving portion 150 of the attachment clip 142 thereby securing the upper panel 112 to the attachment clip 142.
Referring again to FIG. 4, the upper panel 112 may include a stiffener 152 that is secured to upper panel 112 via stiffener clip 154 having an upper portion 156 and a lower portion 158 having a pair of extensions 160. The stiffener clip 154 is secured to the stiffener 152 via fastener 162, such as a screw, extending through the upper portion 156 of the stiffener clip 154 and into the stiffener 152. The pair of extensions 160 of the stiffener clip 154 is received by the stiffener receiving portions 126 of the bottom member 120. The pair of extensions 160 of the stiffener clip 154 and the stiffener receiving portions 126 of the bottom member 120 engage each other through cooperating structure, such as through a friction fit arrangement, detent arrangement, or any other suitable arrangement. The lower panel 114 may also include a stiffener 164 that is secured to the rail 132 of the lower panel 114 via a fastener 166, such as a screw, extending through the lower leg portion 140 of the rail 132 and into the stiffener 164. As shown in FIG. 4, a screen 170 may be positioned between the upper extension 136 of the rail 132 and the bottom member 120 to prevent bugs from passing through this area. Further, as shown in FIG. 5, the upper and lower panels 112, 114 define a space 169 behind the rail 132 between attachments to the support 116 for back ventilation.
The primary difference between the wall panel system 10 shown in FIGS. 2 and 3 and the wall panel system 110 shown in FIGS. 4 and 5 is the engagement arrangement between the bottom members 20, 120 and the attachment clips 32, 132. The hook and grab style arrangement shown in FIGS. 2 and 3 may allow for a more aggressive and high load capacity engagement. The remaining features and benefits, as discussed above, are similar for the wall panel systems 10, 110.
Referring to FIG. 6, a wall panel system 172 according to one embodiment includes left and right panels 174, 176 secured to a support 178 defining a vertical joint 180. The panels 174, 176 each have a generally rectangular (or square) panel body formed by laminating metal skins to a plastic core, although other panel configurations may be utilized. The left and right panels 174, 176 each have a jamb clip 182 positioned at respective ends of the panels 174, 176 adjacent the vertical joint 180. The jamb clips 182 of the left and right panels 174, 176 define a receptor 184 for receiving a vertical spline 186. In particular, each of the jamb clips 182 defines a channel extending the length of the jamb clips 182 that receives a portion of the spline 186. Each of the jamb clips 182 also includes an attachment leg 188 and a bracket receiving portion 190. The jamb clips 182 are secured to respective panels 174, 176 via a fastener 192, such as a screw, extending through the respective panels 174, 176 and jamb clips 182 at the vertical joint 180. A vertical channel 194 is positioned between the support 178 and the jamb clips 182 and allow the panels 174, 176 to be attached to a single stud via a fastener 196, such as a screw. The support 178 may be a bare stud or a stud with sheathing. Insulation, an air, water, vapor barrier, or an insulated composite panel may be positioned between the support 178 and the vertical channel 194. The vertical channel 194 is configured to channel any water that may enter the vertical joint 180 to the base detail (not shown) without contacting an air and water barrier (not shown) behind the panels 174, 176. As shown in FIG. 7, the jamb clips 182 may be eliminated when gasketed vertical joints 198 are utilized. The bracket receiving portion 190 of the jamb clips 182 may receive a fastener bracket 201 to allow attachment of panels 174, 176 along the vertical edge. The fastener bracket 201 may be a single bracket having an extension 203 for engaging respective bracket receiving portions 190 or may be provided as individual brackets on each panel 174, 176.
As shown in FIG. 8, a fastener bracket 201 may be provided as a single member with an extension 203 for engaging the bracket receiving portion 190 of one jamb clip 182 and an engagement member 205 for engaging an engagement receiving portion 207 of the other jamb clip 182. A fastener 209, such as a screw, extends through the fastener bracket 201 for positive panel attachment directly to the channel 194. Furthermore, the securing of the panels 174, 176 to the support 178 through the fastener bracket 201 and channel 194 provides a direct method to take out the dead load of the panel system 172. The attachment leg 188 of the respective jamb clips 182 allows attachment of horizontally oriented stiffeners 211 of the left and right panels 174, 176 via a fastener 213, such as a screw. A return portion 215 of the left and right panels 174, 176 is also configured to act as a stiffener at the panel edge.
The wall panel systems 10, 110 show stiffeners 52, 64, 152, 164 extending in a vertical direction or parallel to the vertical edge of the panels 12, 14, 112, 114. The wall panel system 172 shows stiffeners 211 extending in a horizontal direction or parallel to a horizontal edge of the panels 174, 176. A wall panel having the horizontal joint arrangements shown in FIGS. 2-5 and the vertical joint arrangement shown in FIG. 6 would typically only have stiffeners extending in either the vertical or horizontal direction.
Referring to FIG. 9, a wall panel system 217 may be provided that includes the drained horizontal joint arrangements shown in FIGS. 2-5 along with the splined vertical joint arrangement shown in FIG. 6 to provide the advantages of the spline design for the vertical joint while using a positive drained joint on the horizontal joint. In particular, a first panel 12, 112, 174 is positioned above a second panel 14, 114, 174 with the bottom end of the first panel 12, 112, 174 positioned adjacent to an upper end of the second panel 14, 114, 174 and defining the horizontal joint 18, 118. A third panel 12, 112, 176 is positioned to the right of the first panel 12, 112, 174 with the right side of the first panel 12, 112, 174 positioned adjacent to the left side of the third panel 12, 112, 176 and defining the vertical joint 180. A fourth panel 14, 114, 176 is also positioned below the third panel 12, 112, 176 and to the right of the second panel 14, 114, 174. As discussed above in connection with FIGS. 2-5, each of the panels 12, 14, 112, 114, 174, 176 have bottom members 20, 120 positioned along the bottom edge of the panels 12, 14, 112, 114, 174, 176. The bottom members 20, 120 are spaced from the vertical edges or sides of the panels 12, 14, 112, 114, 174, 176 and are free from engagement with the jamb clips 182. Thus, the bottom members 20, 120 do not fully extend to the vertical joint 180 or jamb and does not require mitered or notched extrusions.
Referring again to FIG. 9, the panels 12, 14, 112, 114, 174, 176 also include jamb clips 182 that receive the spline 186 along the vertical edges of the panels 12, 14, 112, 114, 174, 176 as discussed above in connection with FIGS. 6 and 8. The jamb clips 182 are spaced apart along the vertical edges of the panels 12, 14, 112, 114, 174, 176, but a single jamb clip 182 that extends for most of the panel edge could also be utilized. The jamb clips 182 may be spaced from each other approximately 12-18″ on center. The panels 12, 14, 112, 114, 174, 176, however, may include a gasketed vertical joint as shown in FIG. 7 rather than providing the jamb clips 182. Although not shown, the panels 12, 14, 112, 114, 174, 176 would also include one or more spaced apart attachment clips 42, 142 as discussed above in connection with FIGS. 2-5. As shown in FIGS. 3 and 5, for example, the wall panel system of the present invention provides air/ventilation behind the system to promote drying should the cavity become wetted while minimizing the amount of water getting behind the panel. Further, as shown in FIGS. 10 and 11, an outer face 15 of the panels 12, 14, 112, 114, 174, 176 and an end 33 of the rail 32, 132 define a notch 65 for receiving the vertical spline 186. In particular, the panels 12, 14, 112, 114, 174, 176 are notched back leaving the outer face 15.
Referring to FIGS. 12 and 13, a plurality of wall panels 220 are positioned adjacent to each other thereby forming a wall panel system 222. The wall panels 220 may have the horizontal joint arrangements and the vertical joint arrangements as described above in connection with FIGS. 2-6. The wall panels 220 each have a stiffener 224 extending a longitudinal direction of the panels 220. The stiffeners 224 are generally I-shaped in cross section, although other suitably shaped stiffeners may be utilized. The stiffeners 224 are positioned at about a midpoint of the panels 220 relative to a short dimension of the panels 220. The panels 220 are secured to a support 226 in any suitable manner such as that described above in connection with wall panel systems 10, 110, 172 shown in FIGS. 2-6. As shown in FIGS. 12 and 13, a stiffener clip 228 is secured to one or more of the supports 226. The stiffener clip 228 has a stiffener receiving portion 230 for engaging and receiving the stiffeners 224. The top of FIG. 12 schematically shows the positioning of the stiffener clips 228 relative to the panels 220 and the supports 226. The stiffener receiving portion 230 has a pair of extensions 232 defining a channel 234 therebetween. The longitudinal stiffener 224 is received by the stiffener receiving portion 230, which is configured to take positive and negative loads exerted on the panels 220. In particular, the stiffener 224 engages the stiffener clip 228 such that positive loads exerted on the panel 220 are almost immediately supported by the stiffener clip 228. Further, the stiffener 224 is spaced from one of the extensions 232 of the stiffener clip 228 such that negative loads exerted on the panel 220 will cause the panel 220 to defect outward before the load is transferred to the stiffener clip 228. The longitudinal stiffeners 224 and the stiffener clips 228 substantially eliminate surface deformation of the panels (also known as oil canning) while substantially minimizing stiffener read through.
While several embodiments were described in the foregoing detailed description, those skilled in the art may make modifications and alterations to these embodiments without departing from the scope and spirit of the invention. Accordingly, the foregoing description is intended to be illustrative rather than restrictive.
Patent Application
20110252731
