FLOOR-TO-FLOOR FACADE PANEL MOUNTING SYSTEM

Abstract

Floor-to-floor panel mounting systems may include one or more facade panel hanger assemblies which individually or collectively facilitate mounting and attaching wall panels (e.g., exterior facade panels) to an exterior or interior wall of a building. Each hanger assembly includes one or more vertically extending mounting beams which extend between opposing floor slabs of the building, and which are configured to be operatively coupled to one or more wall panels. Each hanger assembly includes a respective mounting assembly fixed to each of the opposing floor slabs of the building and configured to be operatively coupled the ends of one or more of the mounting beams. The hanger assemblies each include a height adjustment mechanism and a depth adjustment mechanism configured to adjust the positions of the facade panels relative to the wall of the building post-installation of the wall panels on the hanger assemblies.

Description

FIELD

This disclosure relates to systems and methods for mounting facade panels. More specifically, the disclosed embodiments relate to adjustable facade panel mounting systems.

INTRODUCTION

Paneling such as facade panels and cladding is utilized to provide a building interior and/or exterior with aesthetic appeal and/or desirable properties such as fire-resistance, water-resistance, insulation, etc. Facade panel systems are commonly used in commercial, institutional, and residential construction projects and can be customized to meet the specific needs of a building or project. For example, a facade panel system may be designed to include features such as shading and/or ventilation systems. Additionally, in some examples, facade panel systems can be used to provide thermal insulation and energy efficiency to buildings, reduce noise, and improve the overall aesthetic appearance of the structure. Many typical facade panel systems rely on experienced installation professionals to make precise manual adjustments of mounting structures prior to panel attachment. This often leads to incorrect installation of the panels which has many associated financial and safety risks.

SUMMARY

The present disclosure provides systems, apparatuses, and methods relating to wall panel mounting systems.

In some examples, a system for mounting facade panels on a building may include: a hanger assembly configured to mount one or more facade panels on a building, the hanger assembly comprising: a first mounting bracket configured to be fixed to a first floor slab of the building and a second mounting bracket configured to be fixed to a second floor slab, wherein the second floor slab is spaced above the first floor slab; a first mounting beam having a lower end coupled to the first mounting bracket and an upper end coupled to the second mounting bracket, wherein the first mounting beam extends between the first floor slab and the second floor slab transverse to the first and second floor slabs, and wherein the first mounting beam is configured to receive the one or more facade panels; a height-adjustment mechanism configured to selectively translate the one or more facade panels up and down relative to the first and second mounting brackets; and a depth-adjustment mechanism coupled to one or both of the first mounting bracket and the second mounting bracket, wherein the depth-adjustment mechanism is configured to selectively translate one or both ends of the first mounting beam outward and inward relative to the respective mounting bracket.

In some examples, a method of mounting facade paneling on a building may include: fixing a first mounting bracket to a first floor slab of the building and fixing a second mounting bracket to a second floor slab of the building, wherein the second floor slab is spaced above the first floor slab; coupling a lower end of a first mounting beam to the first mounting bracket and an upper end of the first mounting beam to the second mounting bracket, such that the first mounting beam extends between the first floor slab and the second floor slab transverse to the first floor slab and the second floor slab; and coupling one or more facade panels to the first mounting beam.

Features, functions, and advantages may be achieved independently in various embodiments of the present disclosure, or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram representing an illustrative wall panel mounting system in accordance with aspects of the present disclosure.

FIG. 2 is a schematic diagram representing an illustrative hanger assembly of the wall panel mounting system of FIG. 1 in accordance with aspects of the present disclosure.

FIG. 3 is a perspective view of an illustrative wall panel mounting system in accordance with aspects of the present disclosure.

FIG. 4 is a front view of the illustrative wall panel mounting system of FIG. 3.

FIG. 5 is a perspective view of the illustrative panel mounting system of FIG. 3.

FIG. 6 is a perspective view of a mounting beam of the hanger assembly of FIG. 3 in accordance with aspects of the present disclosure.

FIG. 7 is another perspective view of the mounting beam of the hanger assembly of FIG. 3, showing an illustrative interaction between components of the mounting beam.

FIG. 8 is a perspective view of a support beam of the mounting beam of FIG. 3 in accordance with aspects of the present disclosure.

FIG. 9 is a top view of the support beam of FIG. 8.

FIG. 10 is a perspective view of a sliding plate of the hanger assembly of FIG. 3 in accordance with aspects of the present disclosure.

FIG. 11 is a top view of the sliding plate of FIG. 10.

FIG. 12 is a perspective view of a height adjustment mechanism of the hanger assembly of FIG. 3 in accordance with aspects of the present disclosure.

FIG. 13 is a top view of the mounting beam of FIG. 6.

FIG. 14 is a top view of the mounting beam of FIG. 6 with the top cap removed.

FIG. 15 is a partial front view of the mounting beam of FIG. 6.

FIG. 16 is a front partial view of the hanger assembly of FIG. 3 showing a mounting assembly coupled to a first mounting beam and a second mounting beam in accordance with aspects of the present disclosure.

FIG. 17 is a perspective view of the hanger assembly of FIG. 3 installed on a building.

FIG. 18 is a perspective view of the mounting assembly of the hanger assembly of FIGS. 3 and 16.

FIG. 19 is an elevation view of a first side of the mounting assembly of FIG. 18 depicting an illustrative depth adjustment mechanism in accordance with aspects of the present disclosure.

FIG. 20 is an elevation of a second side of the mounting assembly of FIG. 18 depicting a second illustrative depth adjustment mechanism in accordance with aspects of the present disclosure.

FIG. 21 is a perspective view of a mounting bracket of the mounting assembly of FIG. 18.

FIG. 22 is a perspective view of a depth-adjustment body of the depth adjustment mechanisms of FIGS. 19 and 20.

FIG. 23 is front view of a hanger assembly of a panel mounting system installed on a three-story building in accordance with aspects of the present disclosure.

FIG. 24 is a side view of the hanger assembly of FIG. 23.

FIG. 25 is a flow chart depicting steps of an illustrative method for installing the wall panel mounting system on a building in accordance with aspects of the present disclosure.

DETAILED DESCRIPTION

Various aspects and examples of a floor-to-floor facade panel hanging system, as well as related methods, are described below and illustrated in the associated drawings. Unless otherwise specified, a floor-to-floor facade panel hanging system in accordance with the present teachings, and/or its various components, may contain at least one of the structures, components, functionalities, and/or variations described, illustrated, and/or incorporated herein. Furthermore, unless specifically excluded, the process steps, structures, components, functionalities, and/or variations described, illustrated, and/or incorporated herein in connection with the present teachings may be included in other similar devices and methods, including being interchangeable between disclosed embodiments. The following description of various examples is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. Additionally, the advantages provided by the examples and embodiments described below are illustrative in nature and not all examples and embodiments provide the same advantages or the same degree of advantages.

This Detailed Description includes the following sections, which follow immediately below: (1) Definitions; (2) Overview; (3) Examples, Components, and Alternatives; (4) Advantages, Features, and Benefits; and (5) Conclusion. The Examples, Components, and Alternatives section is further divided into subsections, each of which is labeled accordingly.

Definitions

The following definitions apply herein, unless otherwise indicated.

“Comprising,” “including,” and “having” (and conjugations thereof) are used interchangeably to mean including but not necessarily limited to, and are open-ended terms not intended to exclude additional, unrecited elements or method steps.

Terms such as “first”, “second”, and “third” are used to distinguish or identify various members of a group, or the like, and are not intended to show serial or numerical limitation.

“AKA” means “also known as,” and may be used to indicate an alternative or corresponding term for a given element or elements.

“Elongate” or “elongated” refers to an object or aperture that has a length greater than its own width, although the width need not be uniform. For example, an elongate slot may be elliptical or stadium-shaped, and an elongate candlestick may have a height greater than its tapering diameter. As a negative example, a circular aperture would not be considered an elongate aperture.

“Coupled” means connected, either permanently or releasably, whether directly or indirectly through intervening components.

“Rigid” describes a material or structure configured to be stiff, non-deformable, or substantially lacking in flexibility under normal operating conditions.

Directional terms such as “up,” “down,” “vertical,” “horizontal,” and the like should be understood in the context of the particular object in question. For example, an object may be oriented around defined X, Y, and Z axes. In those examples, the X-Y plane will define horizontal, with up being defined as the positive Z direction and down being defined as the negative Z direction.

In this disclosure, one or more publications, patents, and/or patent applications may be incorporated by reference. However, such material is only incorporated to the extent that no conflict exists between the incorporated material and the statements and drawings set forth herein. In the event of any such conflict, including any conflict in terminology, the present disclosure is controlling.

Overview

In general, a floor-to-floor (AKA deck-to-deck, slab-to-slab, etc.) wall panel mounting system in accordance with the present disclosure provides a system for facilitating the installation and post-installation modification of wall panels on a building. To facilitate installation of wall panels, a wall panel mounting system includes a panel support structure configured to fasten to opposing floors of a building and configured to removably couple with one or more wall panels. As such, installing wall panels to a building using the wall panel mounting system includes attaching the wall panels to the panel support structure and fastening the panel support structure to opposing floors of the building. The panel support structure may further include one or more adjustment mechanisms configured to allow an installer to precisely adjust the location of panels post-installation of the panels on the panel support structure. Accordingly, the wall panel mounting system allows an installer to hang one or more wall panels quickly and easily at a plurality of locations on a building and adjust the placement of the one or more hung wall panels post-installation.

The panel support structure of the floor-to-floor wall panel mounting system may include one or more hanger assemblies. Each hanger assembly of the one or more hanger assemblies may include a plurality of mounting beams and a corresponding number of mount assemblies and anchors (e.g., attachment bolts). The panel mounting system spans floor-to-floor, such that the hanger assemblies are coupled to anchors embedded in the floor slabs of the building. By fastening the hanger assemblies to the floor slabs of the building, the panel mounting system avoids any need to couple the hanger assemblies to stud members or other structures disposed between opposing floor slabs of the building. This overcomes inefficiencies and costly construction fees associated with wall attachment styles of previously known mounting systems.

In some examples, each of the mounting beams includes a support beam and a coupling plate (AKA sliding plate) that are configured to be removably fastened to one another. For example, the support beam may include a T-slot formed in a front side of the support beam and the coupling plate may include a t-shaped protrusion configured to be slidingly received within the T-slot to couple the coupling plate to the support beam. The coupling plate is configured to receive the one or more panels, or in other words, the one or more panels are configured to be coupled to the coupling plate either directly or indirectly via interposed panel mounting structures fastened to the coupling plate. The one or more panels may be any type of interior or exterior shell or layer of a building such as cladding, facades, etc. In some examples, the one or more panels are made from materials such as metal, glass, stone, composite materials, etc.

The hanger assemblies each include one or more mount assemblies configured to be fixed to the floor slabs of the building by the anchors embedded in the floor slabs. Each mount assembly includes a mounting bracket fixed to a respective one of the floor slabs and one or more threadless mounting pins configured to couple one or more of the mounting beams to the mounting bracket without the use of a drill or other tools. Utilizing threadless mounting pins to couple the mounting beams to the mounting brackets facilitates accommodating building movement over time.

In some examples, the mounting bracket includes a receiving channel sized to receive a portion of one or more of the mounting beams and one or more mounting pin apertures disposed through the mounting bracket on opposite sides of the channel. Each mounting beam may include corresponding mounting pin slots or apertures extending through the mounting beam and configured to receive the threadless mounting pins. The threadless mounting pins may be inserted through the apertures or slots formed in the mounting bracket and formed in the mounting beam to couple the mounting beam to the mounting bracket. By utilizing the threadless mounting pins, the panel mounting system eliminates the need for any tapping, drilling, and/or screwing to couple the mounting beams to the mounting bracket.

The hanger assembly includes one or more adjustment mechanisms configured to provide multi-directional post-installation adjustability of the one or more panels to an installer. In some examples, the adjustment mechanisms may include a height adjustment mechanism, a width adjustment mechanism, and/or a depth adjustment mechanism which can be actuated by the installer to adjust the arrangement of a panel or panels post-installation of the panel on the hanger assembly. For example, the depth adjustment mechanism is configured to move one or both ends of the mounting beam, and thus the panels fastened to mounting beam, toward and away (e.g., inward and outward) from the mounting brackets, and/or the substrate or walls of the building. In some examples, the height adjustment mechanism is configured to move the coupling plate of the mounting beam, and thus the panels coupled to the coupling plate, up and down in a direction parallel to the walls of the building relative to the support beam of the mounting beam.

In some examples, the height adjustment mechanism is a component of the mounting beam. In some examples, the depth adjustment mechanism is a component of the mounting assembly. Each of the one or more adjustment mechanisms includes an actuator that is easily accessible to the installer, after the panels are mounted on the hanger assemblies, such that height and depth adjustments can be performed post-installation of the panels on the hanger assemblies.

Examples, Components, and Alternatives

The following sections describe selected aspects of illustrative floor-to-floor facade panel mounting systems as well as related methods. The examples in these sections are intended for illustration and should not be interpreted as limiting the scope of the present disclosure. Each section may include one or more distinct embodiments or examples, and/or contextual or related information, function, and/or structure.

A. Schematic Wall Panel Mounting System

As shown in FIGS. 1-2, this section describes an illustrative facade or wall panel mounting system 10. Wall panel mounting system 10 is an example of the facade panel mounting systems, described above. In general, the terms “facade panel” and “wall panel” will be used interchangeably herein, unless otherwise indicated.

FIG. 1 is a schematic diagram representing wall panel mounting system 10 installed on a three-story building 2. Wall panel mounting system 10 comprises one or more facade panel hanger assemblies 12 (AKA hanger assemblies) which individually or collectively facilitate mounting and attaching wall panels (e.g., exterior facade panels) to an exterior or interior wall of building 2. Each hanger assembly 12 comprises a generally vertical mounting structure extending from a bottom floor slab (here, the first-story floor slab) to an upper floor slab (here, the third-story floor slab) of building 2, transverse to the floor slabs. In some examples, each hanger assembly extends straight up and down, e.g., perpendicular or orthogonal to the floor slabs. Alternatively, one or more of the hanger assemblies may extend at an angle (e.g., diagonally) between the floor slabs. Each hanger assembly 12 is attached to floor slabs 4 of building 2. Wall panel mounting system 10 may comprise any suitable number and arrangement of the hanger assemblies 12. In some examples, wall panel mounting system 10 may comprise a plurality of hanger assemblies 12 each extending vertically up the wall of the building and horizontally spaced apart from each other across the wall.

FIG. 2 is schematic diagram representing an individual hanger assembly 12 of wall panel mounting system 10 shown in FIG. 1. As shown in FIG. 2, hanger assembly 12 includes one or more mounting beams 14 (AKA hanger bodies) and a corresponding number of mounting assemblies 16 and anchors 18. Mounting assemblies 16 and anchors 18 facilitate operatively coupling mounting beams 14 to the building and mounting beams 14 are configured to be operatively coupled to one or more wall panels 20.

Anchors 18 may comprise any suitable structure(s) or component(s) configured to be utilized to securely fix mounting assemblies 16 to floor slabs 4 of the building. In some examples, anchors 18 are at least partially embedded in floor slabs 4 to facilitate bearing the weight of the mounting assemblies 16, mounting beams 14, and the wall panels 20. For example, anchors 18 may each comprise one or more threaded bolts, latches, or hooks having a portion embedded in the floor slab 4 and a portion extending outward from floor slab 4 to be coupled to mounting assemblies 16. In some examples, anchors 18 are embedded in opposing floor slabs at identical (or similar) horizontal positions across the wall of the building, such that each of the anchors 18 are vertically aligned with each other and vertically spaced from each other by the distance between opposing or adjacent floor slabs 4. This facilitates forming the vertically extending structures of hanger assembly 12, as described further below.

Each anchor 18 is configured to be fixed to a respective mounting assembly 16. Mounting assemblies 16 may comprise any suitable structures or components configured to be fixed to anchors 18 and to be operatively coupled to one or more of mounting beams 14. In some examples, mounting assemblies 16 comprise a mounting bracket having a base portion that is configured to be fixed to a respective one of anchors 18 and a receiving portion that is configured to receive and securely couple to one or more of mounting beams 14. In some examples, each mounting assembly 16 is configured to be coupled to multiple mounting beams 14. For example, the receiving portion of each mounting assembly 16 may include a receiving channel having a bottom half configured to receive the upper end of a first mounting beam 14 and a top half configured to receive the lower end of a second mounting beam 14. In some examples, the receiving channel is configured to receive the respective ends of the first and second mounting beams, such that the first and second mounting beams 14 are vertically aligned with each other.

Mounting assemblies 16 may comprise any suitable components or fasteners configured to operatively receive and couple to one or more of mounting beams 14. In some examples, mounting assemblies 16 comprise one or more threadless mounting pins configured to extend through one or more slots or apertures formed in both a body (e.g., mounting bracket) of the mounting assembly and the one or more mounting beams to couple mounting assemblies 16 to mounting beams 14. In other words, the mount pin may be configured to couple the mounting assemblies 16 to one or more of mounting beams 14 without the use of tools or drilling. The threadless connection between mounting assemblies 16 and mounting beams 14 facilitates the system accommodating and adjusting for building movement, e.g., to prevent long term failures common in exterior wall coverings.

Mounting beams 14 are configured to extend between adjacent or opposing floor slabs 4 of the building and to have an upper end coupled to a first one of mounting assemblies 16 and a lower end coupled to a second one of mounting assemblies 16. Mounting beams 14 may comprise any suitable structure(s) configured to extend between adjacent or opposing floor slabs 4 and to be operatively coupled to one or more wall panels 20. In some examples, mounting beams 14 comprise a support beam 22 and a sliding plate 24 (AKA hook plate, coupling plate). Support beam 22 includes a rigid structure having the upper end and the lower end coupled to the respective mounting assemblies 16 fixed to the floor slabs of the building. Support beam 22 is sized to span the distance between the opposing floor slabs 4 and to be coupled to mounting assemblies 16. Sliding plate 24 is coupled to a front side of support beam 22 and is configured to be operatively coupled to one or more of wall panels 20 either directly or via any suitable wall panel attachment mechanisms.

Support beam 22 and sliding plate 24 are configured to removably couple with one another by way of a fastening system 26. Fastening system 26 may comprise a first member 28 and a second member 30, with second member 30 configured to securely receive first member 28, for instance in a nesting configuration. Support beam 22 and sliding plate 24 each comprise one member of fastening system 26. In some examples, support beam 22 comprises second member 30 and sliding plate 24 comprises first member 28. Alternatively, in some examples, support beam 22 comprises first member 28 and sliding plate 24 comprises second member 30. In some examples, second member 30 may comprise a T-slot formed in a front side of support beam 22 and first member 28 may comprise any suitable T-shaped insert or fastener extending from a rear side of sliding plate 24 and configured to be slidingly received within the T-slot to secure sliding plate 24 to support beam 22.

Hanger assembly 12 may comprise one or more adjustment mechanisms configured to be utilized to adjust a position of the one or more wall panels 20 post-installation of the wall panels on the mounting beam. For example, mounting beams 14 may comprise a height adjustment mechanism 32 (AKA vertical adjustment mechanism) configured to selectively translate one or more wall panels 20 vertically up and down relative to floor slabs 4 and the wall of the building. In some examples, vertical adjustment mechanism 32 is configured to translate sliding plate 24 up and down relative to support beam 22, such that the one or more wall panels 20 coupled to sliding plate 24 are translated up and down with sliding plate 24. Height adjustment mechanism 32 may comprise any suitable structure(s) configured to translate sliding plate 24 up and down relative to support beam 22. In some examples, height adjustment mechanism 32 comprises an adjustment bolt configured to be actuated to selectively translate an adjuster body up and down relative to support beam 22. The adjuster body may be coupled to sliding plate 24, such that sliding plate 24 is translated up and down with the adjuster body.

In some examples, mounting assemblies 16 comprise a depth adjustment mechanism 34 configured to selectively translate mounting beams 14 towards and away (inward and outward) from the mounting brackets and the respective floor slabs of the building. Wall panels 20 are translated towards or away from the wall of the building with mounting beams 14. Depth adjustment mechanism 34 may comprise any suitable structures configured to selectively translate mounting beam 14 outwards away from the wall of the building and/or inwards and towards the wall of the building. For example, depth adjustment mechanism 34 may comprise an adjustment bolt configured to be actuated (e.g., turned) to selectively translate the mounting beam. In some examples, mounting assemblies 16 may be coupled to the lower end of a first mounting beam and the upper end of a second mounting beam. In such examples, mounting assembly 16 may comprise a first depth adjustment mechanism configured to adjust the horizontal position of the lower end of the first mounting beam and a second depth adjustment mechanism configured to adjust the horizontal position of the upper end of the second mounting beam. The first and second depth adjustment mechanisms may be configured to be actuated independently of one another to facilitate adjusting the inward and outward position of the first and second mounting beams independently of one another.

B. Illustrative Panel Mounting System

As shown in FIGS. 3-25, this section describes an illustrative panel mounting system 100. Panel mounting system 100 is an example of wall panel mounting system 10, described above. Panel mounting system 100 is configured to be utilized to adjustably mount or couple one or more wall panels (e.g., exterior facade panels) to an exterior or interior wall of a building.

FIGS. 3-5 depict an example panel mounting system 100 installed on a portion of an exterior of a multi-story building 2. FIGS. 3-5 show a portion of building 2 extending from just below a first-story floor slab 4 to just above a second-story floor slab 4. Panel mounting system 100 comprises a plurality of facade panel hanger assemblies 102 (AKA hanger assemblies) configured to mount and support a plurality of wall panels 110 (e.g., exterior facade panels) on the exterior wall of building 2. In some examples, panel mounting system 100 is configured to facilitate mounting a plurality of wall panels 110 on an interior wall of a building.

The plurality of hanger assemblies 102 each comprise a structure extending vertically up and down the exterior wall of the building. The plurality of hanger assemblies 102 are spaced apart from each other laterally by any suitable distance across the wall. The plurality of hanger assemblies 102 are configured to individually and/or collectively mount and support one or more facade panels on the exterior wall of the building. Each of hanger assemblies 102 is mounted to floor slabs 4 of the building. In other words, hanger assemblies 102 are configured to extend between opposing floor slabs 4 of the building and are only connected to the building at floor slabs 4. This prevents the need to attach hanger assemblies 102 to stud walls or intermediate fixings disposed between the floor slabs of the building.

As shown in FIGS. 3-5, each hanger assembly 102 comprises one or more mounting beams 104 (AKA hanger bodies) extending between opposing floor slabs of the building and coupled to the opposing floor slabs by mount assemblies 106 and anchors 108. Anchors 108 may comprise any suitable number and arrangement of attachment bolts (e.g., a square) configured to support mounting assemblies 106 and mounting beams 104. The attachment bolts of anchors 108 are partially embedded in both the first-story floor slab and the second-story floor slab at corresponding positions such that the attachment bolts embedded in the first-story floor slab are vertically aligned with the attachment bolts embedded in the second-story floor slab.

Each hanger assembly 102 comprises a respective mounting assembly 106 fixed to each of the anchors. Mounting assembly 106 may comprise any suitable structure configured to be fixed to anchor 108 and to be coupled to one or more of mounting beams 104, as described further below with reference to FIGS. 16-22. Each mounting assembly is configured to be coupled to a lower end of first mounting beam 104 and an upper end of a second mounting beam 104. Each of mounting beams 104 extends between opposing floor slabs of the building and has a respective upper end coupled to a first mounting assembly 106 and a respective lower end coupled to a second mounting assembly 106.

In some examples, mounting assemblies 106 are arranged (e.g., vertically aligned with each other), such that mounting beams 104 of each hanger assembly extend vertically in a straight-line up and down the wall of the building perpendicular to the floor slabs. In some examples, mounting assemblies 106 may be offset from another, such that mounting beams 104 of each hanger assembly extend diagonally between opposing floor slabs transverse to the floor slabs.

FIGS. 6-15 depict an illustrative example of a mounting beam 104 of hanger assemblies 102 shown in FIGS. 3-5. As shown in FIGS. 6-15, mounting beam 104 comprises a support beam 112 (AKA support body) and a coupling plate 114 (AKA hook plate, sliding plate) operatively coupled to support beam 112. Support beam 112 has a lower end 132 configured to be coupled to a first one of mounting assemblies 106 and an upper end 134 configured to be coupled to a second one of mounting assemblies 106. In other words, support beam 112 is the portion of mounting beam 104 that is configured to be operatively coupled to the mounting assemblies of the hanger assembly 102. Sliding plate 114 is operatively coupled to a front side of support beam 112. Sliding plate 114 is configured to be operatively coupled to one or more facade panels 110 either directly or indirectly via any suitable panel coupling mechanism mounted on sliding plate 114.

Sliding plate 114 and support beam 112 may be coupled to each other in any suitable manner configured to permit selective up and down translation of sliding plate 114 relative to support beam 112. For example, as shown in FIG. 9, support beam 112 may comprise a T-slot, channel, or track 124 formed in the front side of support beam 112 and running the longitudinal or vertical length of support beam 112. As shown in FIG. 11, sliding plate 114 may comprise a corresponding t-shaped protrusion 122 extending from a rear side of sliding plate 114 and configured to be received in T-slot 124 to slidingly couple sliding plate 114 to support beam 112. For example, as shown in FIG. 7, t-shaped protrusion 122 may be slid into T-slot 124 from a bottom end of support beam 112 to couple sliding plate 114 to support beam 112.

As shown in FIGS. 8 and 9, support beam 112 comprises a hollow rectangular beam having T-slot 124 formed in the front side of support beam 112. Support beam 112 includes top end 130 and bottom end 132 configured to couple with respective mount assemblies 106 on opposing (e.g., consecutive) floor slabs of the building. In some examples, support beam 112 installed, such that mounting beam 104 is arranged perpendicular to and coupled to both floor slabs by the mounting assemblies. Support beam 112 is typically sized such that it spans a little more than the distance between the opposing floor slabs to securely fasten with mount assemblies 106 on both ends.

As shown in FIG. 9, support beam 112 is hollow and comprises an internal compartment 174 extending from top end 130 of support beam 112 through and out bottom end 132. In some examples, internal compartment 174 extends only partially through support beam 112. A top portion 176 of internal compartment 174 disposed in top end 130 of support beam 112 comprises a pair of screw guides 178 that protrude inwards from the sides of support beam 112 into internal compartment 174. As shown in FIG. 9, screw guides 178 are disposed towards a front portion of internal compartment 174. In some examples, screw guides 178 are each configured to receive a respective screw 166 to couple a top cap 150 of mounting beam 104 to support beam 112.

Support beam 112 includes a fixed mounting pin aperture 126 disposed adjacent top end 130 of support beam 112 and an unfixed mounting pin aperture 128 disposed adjacent bottom end 132 of support beam 112. Fixed mounting pin aperture 126 and unfixed mounting pin aperture 128 are configured to receive respective threadless mounting pins of mounting assemblies 106 to couple mounting beam 104 to mounting assemblies 106. Both fixed mounting pin aperture 126 and unfixed mounting pin aperture 128 extend through an entirety of support beam from a left side of the support beam to a right side of the support beam. As depicted in FIG. 8, fixed mounting pin aperture 126 comprises a round aperture sized to receive a threadless mounting pin of mounting assembly 106 to facilitate coupling the mounting beam to the mounting assembly. Unfixed mounting pin aperture 128 comprises an oblong aperture shaped to receive a threadless mounting pin of mounting assembly 106. Unfixed mounting pin aperture 128 has an oblong shape to accommodate variations in the spacing between the mounting assemblies fixed to the opposed floor slabs, as well as accommodating building movement overtime.

Sliding plate 114 is configured to be slidingly coupled to support beam 112 and to receive or be coupled to one or more wall panels 110. As shown in FIGS. 10 and 11, sliding plate 114 includes at least a main structural body 140 having a top end 170 and a bottom end 172, a T-shaped protrusion 122 extending rearward from main structural body 140, and one or more panel mount receivers 142 disposed on a front side of main structural body 140. One or more panel mount receivers 142 may comprise any suitable structures configured to facilitate mounting or receiving one or more panels on sliding plate 114 either directly or indirectly via interposed plate mounting mechanisms. In the example of FIGS. 10 and 11, one or more panel mount receivers 142 comprise a pair of T-slot mounting apertures running a longitudinal or vertical length of sliding plate 114. The T-slot mounting apertures are configured to receive any suitable standard mounting mechanisms configured to facilitate coupling the one or more wall panels to sliding plate 114. In some examples, a portion of the suitable standard mounting mechanisms may be received within the T-slot mounting apertures to couple the mounting mechanisms to sliding plate 114 and the wall panels may then be attached to the mounting mechanisms. In some examples, the panels include one or more protrusions which are received by one or more panel mount receivers 142 to directly couple the one or more wall panels to sliding plate 114.

As shown in FIG. 11, sliding plate 114 includes T-shaped protrusion 122 protruding rearward from a rear side of sliding plate 114 and one or more panel mount receivers 142 formed in a front side of coupling plate 114. This facilitates sliding plate 114 being configured to interact with and couple to support beam 112 on the rear side, and to interact and couple with one or more wall panels 110 on the front side. The rear side of sliding plate 114 and the front side of support beam 112 are configured to interact with one another by way of the T-shaped track 124 and T-shaped protrusion 122 to selectively couple and uncouple sliding plate 114 to and from support beam 112.

Mounting beam 104 comprises a height adjustment mechanism 134 configured to adjust a vertical position of sliding plate 114 relative to support beam 112. Height adjustment mechanism 134 may comprise any suitable components and/or structures configured to facilitate a user selectively translating sliding plate 114 up and down relative to support beam 112 to move wall panels 110 fixed to coupling plate 114 to different heights relative to support beam 112. For example, as shown in FIGS. 12-15, height adjustment mechanism 134 may comprise a height adjuster 146 including an adjuster body 154 having a threaded bore 160 receiving an adjustment bolt 148 (AKA control rod). Adjustment bolt 148 is coupled at an upper end to top cap 150 of mounting beam 104. When installed on mounting beam 104, height adjuster 146 is configured, such that turning adjustment bolt 148 translates adjuster body 154 up and down along adjustment bolt 148. Adjuster body 154 is coupled to sliding plate 114, such that sliding plate 114 is translated up and down relative to support beam 112 with adjuster body 154, as described further below.

FIGS. 12-14 depict top cap 150 of height adjustment mechanism 134. Top cap 150 comprises a rectangular plate 162 sized to fit over top end 130 of support beam 112. Top cap 150 further comprises a pair of screw apertures 164 and an adjustment bolt aperture 161 disposed through rectangular plate 162. Adjustment bolt aperture 161 is sized to receive adjustment bolt 148. As shown in FIG. 13, adjustment bolt aperture 161 of top cap 150 is disposed adjacent a center of rectangular plate 162 between screw apertures 164. Screw apertures 164 of top cap 150 and screw guide tracks 158 of adjuster body 154 are spaced on either side of adjustment bolt aperture 161 and threaded bore 160 of adjuster body, respectively. Height adjustment mechanism 134 further comprises one or more nuts 168 configured to secure adjustment bolt 148 to top cap 150. Adjustment bolt 148 is secured to top cap 150 by inserting adjustment bolt 148 through adjustment bolt aperture 161 and tightly fastening one or more nuts 168 to adjustment bolt 148.

When top cap 150 is installed on mounting beam 104, vertical adjuster 146 is received within a front portion of internal compartment 174 of support beam 112, such that screw guides 178 of support beam 112 are received within screw guide tracks 158 of adjuster body 154. Screw apertures 164 of top cap 150 are vertically aligned with the screw guides 178 of support beam 112 disposed within screw guide tracks 158 of vertical adjuster 146, such that screws 166 can be inserted through screw apertures 164 and into screw guides 178 to fasten top cap 150 to support beam 104. Screws 166 fasten top cap 150 directly to screw guides 178 of support beam 112 and do not fasten to adjuster body 154 to permit up and down translation of adjuster body 154 relative to top cap 150.

Screw guides 178 of support beam 112 received within screw guide tracks 158 of adjuster body 154 prevent adjuster body 154 from rotating with adjustment bolt 148, when adjustment bolt 148 is turned or rotated. As a result, rotating adjustment bolt 148 translates adjuster body 154 up and down adjustment bolt 148 which is fixed to top cap 150. Thus, by rotating adjustment bolt 148 in a first direction, adjuster body 154 is translated upward and by rotating adjustment bolt 148 in an opposite second direction, adjuster body 154 is translated downward. Screw guides 178 received within screw guide tracks 158 guide adjuster body 154 in a straight line up and down within internal compartment 174 of support beam 112.

Adjuster body 154 is configured to be coupled to sliding plate 114, such that translating adjuster body 154 up and down relative to top cap 150 using adjustment bolt 148 causes sliding plate 114 to be translated up and down relative to support beam 112. For example, sliding plate 114 may be coupled to adjuster body 154 by a plurality of vertical-adjustment fasteners 152 (e.g., screws) inserted through a plurality of coupling-plate apertures 144 formed in sliding plate 114 and a corresponding plurality of adjuster-body apertures 156 formed in adjuster body 154. As shown in FIGS. 8 and 15, support beam 112 includes a pair of height-adjustment slots 138 formed in a front side of support beam 112, e.g., within T-slot 124. Vertical-adjustment fasteners 152 are configured to extend through height-adjustment slots 138 to couple sliding plate 114, which is disposed external to support beam 112, to adjuster body 154 which is disposed within internal compartment 174 of support beam 112. Vertical-adjustment slots 138 have an elongate shape and may have any suitable vertical length configured to limit the up and down translation of adjuster body 154 and sliding plate 114 caused by rotating adjustment bolt 148.

Accordingly, height adjustment mechanism 134 including height adjuster 146 is configured to be actuated to selectively translate sliding plate 114 vertically up and down relative to support beam 112. Rotating adjustment bolt 148 in a first direction translates adjuster body 154 upwards relative to top cap 150 of support beam 112. Rotating adjustment bolt 148 in the opposite second direction translates adjuster body 154. Sliding plate 114 is coupled to adjuster body 154 via screws extending through vertical-adjustment slots 138 formed in support beam 112, such that sliding plate 114 is translated up and down with adjuster body 154. The maximum and minimum height that can be reached by sliding plate 114 relative to top cap 150 is determined by the size of vertical-adjustment slots 138 formed in front side of support beam 112.

Components of mounting beam 104 (e.g., sliding plate 114 and support beam 112) may comprise any suitable materials configured to support wall panels 110. In some examples, sliding plate 114 and support beam 112 each comprise a rigid material that is configured to support wall panels 110. For example, sliding plate 114 and support beam 112 may comprise extruded aluminum or other rigid metal material.

Each mounting beam 104 of hanger assembly 102, described above, is configured to be coupled at each end to a respective mounting assembly 106 fixed to a respective floor slab 4 of the building. FIGS. 16-22 depict an illustrative example of mounting assembly 106 configured to be operatively coupled to one or more of mounting beams 104. As shown in FIGS. 16-17, mounting assembly 106 is configured to be operatively coupled to a lower end 132 of a first mounting beam 104A and an upper end 134 of a second mounting beam 104B. Mounting beams 104A and 104B are the same as mounting beam 104, described above with reference to FIGS. 6-15.

Mounting assembly 106 shown in FIG. 16 is fixed to a second-story floor slab 4 of a building. In some examples, as shown in FIGS. 23 and 24, first mounting beam 104A may extend between second-story floor slab and a third-story floor slab spaced above the second-story floor slab. Second mounting beam 104B may extend between the second-story floor slab and a first-story floor slab spaced below the second-story floor slab. An identical mounting assembly 106 may be fixed to the third-story floor slab and the first-story floor slab to couple to the upper end of first mounting beam 104A and lower end of second mounting beam 104B. In some examples, mounting assembly 106 is configured to vertically align first mounting beam 104A with second mounting beam 104B, such that hanger assembly 102 includes a plurality of mounting beams 104 collectively extending vertically in a straight line up the wall of the building. At each floor slab of the building (e.g., first-story, second-story, and third-story floor slabs) a respective mounting assembly 106 is fixed to a respective anchor 108 and each respective mounting assembly 106 may be vertically aligned with the other mounting assemblies fixed to the other floor slabs.

Mounting assembly 106 includes a mounting bracket 200. Mounting bracket 200 may comprise any suitable structure(s) configured to interface with and be coupled to anchor 108 embedded in the floor slab of the building and to interface with and be operatively coupled to one or more mounting beams 104. For example, mounting bracket 200 may include a base plate 202 configured to abut floor slab 4 and to be fixed to anchor 108 and a pair of parallel plates 204A, 204B extending outward from base plate 202 parallel to each other. Base plate 202 includes one or more anchor apertures 206 configured to facilitate fixing base plate to anchor 108. For example, as shown in FIGS. 17, anchor 108 may include one or more mounting bolts partially embedded in floor slab 4 and each of anchor apertures 206 receives a respective one of the mounting bolts to fix base plate 202 to the anchor.

When base plate 202 is fixed to anchor 108, parallel plates 204A, 204B of mounting bracket 200 extend outward from the floor slab parallel to one another, such that a receiving channel 208 is defined between the pair of parallel plates 204A, 204B and the portion of base plate 202 disposed between the parallel plates. Receiving channel 208 is configured to receive the respective end of one or more of mounting beams 104. For example, receiving channel 208 is configured to receive upper end 134 of second mounting beam 104B and lower end 132 of first mounting beam 104A. Parallel plates 204A, 204B may be spaced apart from each other by any suitable distance to facilitate receiving channel 208 being sized and shaped to receive and accommodate mounting beams 104A and 104B.

Parallel plates 204A, 204B of mounting bracket 200 each include one or more upper mounting pin apertures 210A and one or more lower mounting pin apertures 210B each configured to receive a threadless mounting pin 212A, 212B to couple mounting bracket 200 to mounting beams 104A and 104B, respectively. Threadless mounting pins 212A, 212B are configured to extend through upper or lower mounting pin apertures 210A, 210B formed in parallel plates 204A, 204B and through fixed or unfixed mounting pin apertures 126, 128 formed in the ends of mounting beams 104, as described above. For example, a first threadless mounting pin 212A extends through upper mounting pin apertures 210A formed in parallel plates 204A, 204B and through unfixed mounting pin aperture 128 formed proximate lower end 132 of mounting beam 104A to couple mounting beam 104A to mounting bracket 200. A second threadless mounting pin 212B extends through lower mounting pin apertures 210B formed in parallel plates 204A, 204B and through fixed mounting pin aperture 126 formed proximate upper end 134 of second mounting beam 104B to couple second mounting beam 104B to mounting bracket 200.

Threadless mounting pins 212A, 212B may comprise any suitable threadless fastener configured to extend through the apertures formed in the parallel plates and the mounting beams to couple the mounting beams to the mounting bracket 200. In some examples, threadless mounting pins 212A, 212B comprise any suitable clevis pin configured to selectively and removably couple mounting beam 104A, 104B to mounting bracket 200. Utilizing threadless mounting pins 212A, 212B to couple mounting bracket 200 to mounting beams 104A, 104B facilitates accommodating building movement which commonly causes failures in exterior wall coverings. Furthermore, utilizing the threadless mounting pins 212A, 212B facilitates coupling mounting beams 104A, 104B to mounting bracket 200 without requiring the use of a drill or other tools. As described above, unfixed mounting pin aperture 128 formed proximate the lower end of mounting beam 104A has an elongate shape configured to permit up and down motion of mounting pin 212A within unfixed mounting pin aperture 128. Permitting up and down motion of mounting pin 212A within unfixed mounting pin aperture 128 facilitates wall panel mounting system 100 accommodating building movement.

Mounting assembly 106 includes a first depth adjustment mechanism 216A configured to facilitate adjusting a horizontal depth or position of first mounting beam 104A and a second depth adjustment mechanism 216B configured to facilitate adjusting the horizontal depth or position of second mounting beam 104B. First and second depth adjustment mechanisms 216A, 216B may comprise any suitable structures, components, or mechanisms configured to facilitate a user (e.g., an installer of the wall panel assembly 100) selectively adjusting a horizontal depth or position of the first and second mounting beams 104A and 104B relative to the floor slab 4 and mounting bracket 200. Put another way, actuating first depth adjustment mechanism 216A is configured to translate lower end 132 of first mounting beam 104A inwards and outwards (e.g., horizontally) relative to mounting bracket 200 and floor slab 4 and actuating second depth adjustment mechanism 216B is configured to translate upper end 134 of second mounting beam 104B inwards and outwards (e.g., horizontally) relative to mounting bracket 200 and floor slab 4. First depth adjustment mechanism 216A and second depth adjustment 216B are configured to be independently adjustable, such that a user can selectively adjust the horizontal position of the first mounting beam 104A and the second mounting beam 104B independently of one another.

As shown in FIG. 18, first depth adjustment mechanism 216A is coupled to a first one of parallel plates 204A and second adjustment mechanism 216B is coupled to a second one of parallel plates 204B. FIG. 19 illustrates a side view of mounting bracket 200 from the side of first parallel plate 204A. As shown in FIG. 19, first depth adjustment mechanism 216A is coupled to first parallel plate 204A and comprises a depth-adjustment bolt 218 and a depth-adjustment body 220 having a threaded bore 222 configured to receive depth-adjustment bolt 218. Depth-adjustment bolt 218 is coupled at a first end to a distal flange of parallel plate 204A and at a second end to base plate 202 of mounting bracket 200. A user may rotate depth-adjustment bolt 218 and rotating depth-adjustment bolt 218 is configured to translate depth-adjustment body 220 towards or away from base plate 202 of mounting bracket 200. FIG. 20 depicts a side view of mounting bracket 200 from the side of parallel plate 204B. As shown in FIG. 20, second depth adjustment mechanism 216B is substantially identical to first depth adjustment mechanism 216A and includes a depth-adjustment bolt 218 and a depth-adjustment body 220. Components of first depth adjustment mechanism 216A are inverted relative to second depth adjustment mechanism 216B, such that first depth adjustment mechanism 216A is configured to operatively couple to lower end 132 of first mounting beam 104A, whereas second depth adjustment mechanism 216B is configured to operatively couple to upper end 134 of second mounting beam 104B disposed below lower end 132 of first mounting beam 104A.

As shown in FIG. 22 depicting depth-adjustment body 220 of first and second depth-adjustment mechanisms 216A, 216B, depth-adjustment body 220 includes a rigid body having a mounting-pin bore 226 proximate a first end of the rigid body and a flange 228 disposed at a second opposite end of the rigid body. Mounting-pin bore 226 is configured to receive threadless mounting pin 212A or 212B to couple depth-adjustment body 220 to the respective mounting beam 104A or 104B. Flange 228 is configured to be received within a guide channel 230 formed in parallel plate 204A, 204B of mounting bracket 200. Guide channel 230 is configured to guide depth-adjustment body 220, when depth-adjustment body 220 is translated horizontally by rotating depth-adjustment bolt 218.

Accordingly, first depth adjustment mechanism 216A includes a depth-adjustment body 220 operatively coupled to lower end 132 of first mounting beam 104A by threadless mounting pin 212A. First depth adjustment mechanism 216A includes a depth-adjustment bolt 218 received in threaded bore 222 of depth-adjustment body 220 and depth-adjustment bolt 218 is configured to be rotated to selectively translate depth-adjustment body 220 towards and away from base plate 202 of mounting bracket 200. Depth-adjustment body 220 includes flange 228 received within guide channel 230 of parallel plate 204 and guide channel 230 is configured to guide the horizontal translation of depth-adjustment body 220 relative to base plate 202. Lower end 132 of first mounting beam 104A is selectively translated inwards and outwards from base plate 202 and floor slab 204 with depth-adjustment body 220. Second depth adjustment mechanism 216B is substantially identical to first depth adjustment mechanism 216A, but operatively coupled to second mounting beam 104B. Thus, actuating second depth adjustment mechanism 216B is configured to selectively translate upper end 134 of second mounting beam 104B towards and away (e.g., inwards and outwards) from base plate 202 of mounting bracket 200 and floor slab 4. First and second depth adjustment mechanisms 216A, 216B are each configured to be adjusted independently of one another, such that the respective horizontal position of first mounting beam 104A and second mounting beam 104B are selectively adjustable independently of one another.

C. Illustrative Method

This section describes steps of an illustrative method 300 for installing external and/or internal paneling using panel mounting systems 10 or 100; see FIG. 25. Aspects of panel mounting systems 10 and 100 may be utilized in the method steps described below. Where appropriate, reference may be made to components and systems that may be used in carrying out each step. These references are for illustration, and are not intended to limit the possible ways of carrying out any particular step of the method.

FIG. 25 is a flowchart illustrating steps performed in an illustrative method, and may not recite the complete process or all steps of the method. Although various steps of method 300 are described below and depicted in FIG. 25, the steps need not necessarily all be performed, and in some cases may be performed simultaneously or in a different order than the order shown.

Step 302 of method 300 includes partially embedding anchors (e.g., attachment bolts) in the building floor slab or floor substrate. The attachment bolts are partially embedded in the floor slab, such that a portion of the attachment bolts extends out of an exterior side of the floor substrate. In some examples, the attachment bolts are embedded in the floor slab during the pouring of the floor substrate. In some examples, step 304 comprises drilling one or more holes into the floor slab. The one or more holes are sized (e.g., 0.438 in) to receive an attachment bolt. This step may further include blowing out the holes and using a sleeve or epoxy to secure the attachment bolt to the floor slab. In some examples, four holes may be drilled at each determined location, in some desired arrangement such as, for example, in a square or rectangular pattern.

Step 304 of method 300 includes attaching each mounting assembly of a panel hanger assembly to the floor slabs. In some examples, step 304 includes securing a mounting bracket of the mounting assembly to the attachment bolts embedded in the floor slab. In some examples, the mounting bracket comprises a pair of parallel plates that define a receiving channel.

Step 306 of method 300 includes attaching one or more mounting beams of the hanger assembly to the mount assemblies that are secured to the floor slabs by the attachment bolts. In some examples, step 306 includes placing the mounting beam between the pair of parallel plates of the mounting bracket within the receiving channel. In some examples, the mounting assemblies include a mounting pin and step 308 includes inserting the mounting pin through one or more apertures formed in the mounting assembly parallel plates and formed through the mounting beam to secure the mounting beam to the mount assembly.

In some examples, each mounting bracket is configured to be secured to the upper end of a first mounting beam and to the lower end of a second mounting beam positioned above the first mounting beam. In such examples, the upper end of the first mounting beam and the lower end of the second mounting beam are both received within the receiving channel formed between the parallel plates of the mounting bracket. In such examples, step 306 may include inserting a first mounting pin through the parallel plates and an aperture formed proximate the upper end of the first mounting beam and inserting a second mounting pin through the parallel plates and an aperture formed proximate the lower end of the second mounting beam.

Step 308 of method 300 is optional and includes fastening a coupling plate of the mounting beam to a support beam of the mounting beam via a fastening system. In some examples, the coupling plate is fastened to the support beam prior to coupling the mounting beam to the mounting brackets in step 306. Coupling the coupling plate to the support beam may include sliding a T-shaped coupling protrusion of the coupling plate into a T-slot formed in a front side of the support beam to couple the coupling plate to the support beam.

Step 310 of method 300 is optional and includes adding exterior insulation between each hanger assembly.

Step 312 of method 300 includes mounting facade panels onto the coupling plate of the hanger assembly. The coupling plate may be configured to receive or couple to the facade panels in any suitable manner. For example, the facade panels may include one or more mounting protrusions disposed on a back of the facade panel(s) which are configured to be slidingly received within corresponding mounting tracks disposed on a front of the coupling plate. In some examples, the coupling plate includes mounting tracks which are configured to receive one or more panel mounting structures or mechanisms and the facade panels are configured to be coupled to the one or more panel mounting structures or mechanisms.

Step 316 of method 300 is optional and includes adjusting panel placement. This step includes actuating one or more of the adjustment mechanisms of hanger assembly to change the positioning of one or more of the facade panels post-installation. In some examples, this step includes actuating a depth adjustment mechanism by turning an adjuster screw of the mounting assembly. In such examples, the turning or rotating the adjuster screw is configured to translate the respective end of the mounting beam coupled to the mounting assembly in or out relative to the mounting bracket of the mounting assembly and the wall of the building.

In some examples, step 316 includes actuating a height adjustment mechanism which is configured to translate the coupling plate of the mounting beam up and down relative to the support beam of the mounting beam. The one or more facade panels coupled to the coupling plate are also translated up and down with the coupling plate. In some examples, actuating the height adjustment mechanism comprises turning or rotating a height-adjustment bolt.

Both the depth-adjustment mechanism and the height-adjustment mechanism are configured to be actuated post-installation of the panels on the hanger assemblies. In other words, the actuators (e.g., adjustment bolts) of the depth-adjustment mechanisms and the height-adjustment bolts are configured to be accessible by an installer after the panels have been installed, such that the installer is able to adjust the panels post-installation.

D. Illustrative Combinations and Additional Examples

This section describes additional aspects and features of wall panel mounting systems, presented without limitation as a series of paragraphs, some or all of which may be alphanumerically designated for clarity and efficiency. Each of these paragraphs can be combined with one or more other paragraphs, and/or with disclosure from elsewhere in this application, including the materials incorporated by reference in the Cross-References, in any suitable manner. Some of the paragraphs below expressly refer to and further limit other paragraphs, providing without limitation examples of some of the suitable combinations.

• • A0. A system for mounting facade paneling on a building, the system comprising:
    • one or more hanger assemblies each configured to mount one or more facade panels on the building, each of the one or more hanger assemblies comprising:
      • two or more anchors each embedded in a respective floor slab of the building, such that the two or more anchors are vertically aligned with each other and vertically spaced from each other;
      • one or more mounting beams configured to be operatively coupled to one or more facade panels and to extend between an opposing pair of the floor slabs; and
      • a respective mounting bracket fixed to each of the two or more anchors, wherein each respective mounting bracket is operatively coupled to at most two of the one or more mounting beams;
      • wherein each of the one or more mounting beams has an upper end operatively coupled to a first one of the mounting brackets and a lower end operatively coupled to a second one of the mounting brackets, and wherein each of the mounting beams extends between the opposing pair of the floor slabs perpendicular to the floor slabs.
  • A1. The system of paragraph A0, wherein each of the one or more mounting beams comprises:
    • a support beam comprising the upper end operatively coupled to the first one of the mounting brackets and the lower end operatively coupled to the second one of the mounting brackets; and
    • a coupling plate operatively coupled to a front side of the support beam and configured to be operatively coupled to one or more of the facade panels.
  • A1.1. The system of paragraph A1, wherein each of the one or more mounting beams comprises a vertical adjustment mechanism coupling the coupling plate to the support beam, such that the coupling plate is configured to be selectively translated to different heights relative to the support beam.
  • A1.2. The system of paragraph A1.1, wherein selectively translating the coupling plate to different heights relative to the support beam is configured to adjust a height of the one or more facade panels coupled to the coupling plate relative to the opposing floor slabs.
  • A1.3. The system of paragraph A1.1 or A1.2, wherein the vertical adjustment mechanism comprises an adjustment bolt configured to be actuated to translate the coupling plate to the different heights relative to the support beam.
  • A2. The system of any one of paragraphs A0-A1.3, wherein each respective mounting bracket comprises a base plate configured to be fixed to the anchor and a pair of parallel plates extending from the base plate parallel to each other to define a channel, and wherein the channel is configured to receive a respective end of at most two of the one or more mounting beams.
  • A2.1. The system of paragraph A2, wherein the channel is configured to receive the lower end of a first one of the mounting beams and the upper end of a second one of the mounting beams.
  • A2.2 The system of paragraph A2.1, wherein the mounting bracket comprises a first horizontal adjustment mechanism operatively coupled to the lower end of the first one of the mounting beams and a second horizontal adjustment mechanism operatively coupled to the upper end of the second one of the mounting beams, wherein the first horizontal adjustment mechanism is configured to selectively translate the first one of the mounting beams towards and away from the floor slabs, and wherein the second horizontal adjustment mechanism is configured to selectively translate the second one of the mounting beams towards and away from the floor slabs, wherein the first and second horizontal adjustment mechanisms permit independent adjustment of the horizontal position of the one of the mounting beams and the second one of the mounting beams.
  • A2.3. The system of paragraph A2.2, wherein the first and second horizontal adjustment mechanisms each comprise a respective adjustment bolt configured to be actuated to selectively translate the respective one of the mounting beams towards and away from the floor slabs.
  • A3. The system of any one of paragraphs A-A2.3, wherein each respective mounting bracket further comprises:
    • at least one mounting pin operatively coupling the mounting bracket to the one or more mounting beams, wherein the at least one mounting pin extends through a slot in the one of the one or more mounting beams.
  • A3.1. The system of paragraph A3, wherein the at least one mounting pin is threadless.
  • A4. The system of any one of paragraphs A-A3.1, wherein each of the two or more anchors comprises one or more bolts embedded in the respective floor slab.
  • A5. The system of any one of paragraphs A-A4, wherein the one or more hangar assemblies comprises a plurality of the hangar assemblies each spaced from each other across an exterior wall of the building.
  • B0. A system for mounting facade paneling on a building, the system comprising:
    • one or more hanger assemblies each configured to mount one or more facade panels on the building, each of the one or more hanger assemblies comprising:
      • a first anchor embedded in a first floor slab of the building and a second anchor embedded in a second floor slab of the building, wherein the second floor slab is spaced above the first floor slab and opposed to the first floor slab;
      • a first mounting bracket fixed to the first anchor and a second mounting bracket fixed to the second anchor;
      • a first mounting beam having a lower end coupled to the first mounting bracket and an upper end coupled to the second mounting bracket, wherein the first mounting beam extends between the first floor slab and the second floor slab perpendicular to the first and second floor slabs, and wherein the first mounting beam is configured to be operatively coupled to one or more facade panels.
  • B1. The system of paragraph B0, wherein the first mounting beam comprises:
    • a support beam comprising the upper end operatively coupled to the first one of the mounting brackets and the lower end operatively coupled to the second one of the mounting brackets; and
    • a coupling plate operatively coupled to a front side of the support beam and configured to be operatively coupled to one or more of the facade panels.
  • B1.1. The system of paragraph B1, wherein the first support beam comprises a horizontal adjustment mechanism coupling the coupling plate to the support beam, such that the coupling plate is configured to be selectively translated to different heights relative to the support beam.
  • B1.2. The system of paragraph B1.1, wherein selectively translating the coupling plate to different heights relative to the support beam is configured to adjust a height of the one or more facade panels coupled to the coupling plate relative to the opposing floor slabs.
  • B1.3. The system of any one of paragraphs B1-B1.2, wherein the coupling plate is slidingly coupled to the support beam.
  • B1.4. The system of paragraph B1.3, wherein the support beam includes a T-slot formed in a front side of the support beam, and wherein the coupling plate includes a corresponding t-shaped protrusion configured to be slidingly received within the T-slot to couple the coupling plate to the support beam.
  • B2. The system of any one of paragraphs B0-B1.4, wherein each of the first mounting bracket and the second mounting bracket comprises a respective horizontal adjustment mechanism operatively coupling the first mounting beam to the first and second mounting brackets respectively.
  • B2.1. The system of paragraph B2, wherein the respective horizontal adjustment mechanisms are configured to selectively translate the first mounting beam towards and away from the opposing floor slabs.
  • B3. The system of any one of paragraphs B0-B2.1, wherein each mounting bracket comprises a base plate fixed to the respective anchor and a pair of parallel plates projecting from the base plate to define a channel, wherein the channel is configured to receive the respective end of the first mounting beam.
  • B4. The system of any one of paragraphs B-B3, further comprising:
    • a third anchor fixed to a third floor slab spaced above the second floor slab and opposed to the second floor slab, wherein the third anchor is vertically aligned with the first and second anchors;
    • a third mounting bracket fixed to the third anchor;
    • a second beam having a second-beam lower end operatively coupled to the second mounting bracket and a second-beam upper end operatively coupled to the third mounting bracket.
  • B4.1. The system of paragraph B4, wherein the second mounting bracket comprises a first horizontal adjustment mechanism operatively coupled to the upper end of the first mounting beam and a second horizontal adjustment mechanism operatively coupled to the second-beam lower end of the second mounting beam.
  • B4.2. The system of paragraph B4.1, wherein the first horizontal adjustment mechanism is configured to selectively translate the upper end of the first mounting beam towards and away from the second floor slab and the second horizontal adjustment mechanism is configured to selectively translate the second-beam lower end towards and away from the second floor slab.
  • B4.3. The system of paragraph B4.1 or B4.2, wherein the first horizontal adjustment mechanism and the second horizontal adjustment mechanism are configured to be adjustable independently.
  • B4.4. The system of any one of paragraphs A4.1-A4.3, wherein the first horizontal adjustment mechanism and the second horizontal adjustment mechanism each comprise an adjustment bolt configured to be actuated to selectively translate the respective mounting beam towards and away from the second floor slab.
  • B5. The system of any one of paragraphs B-B4.4, wherein the first mounting bracket and the second mounting bracket each comprise a threadless mounting bolt operatively coupling the first mounting bracket to the lower end of the first mounting beam and the second mounting bracket to the upper end of the first mounting beam.
  • B5.1. The system of paragraph B5, wherein the upper end of the first mounting beam comprises a bore extending through the first mounting beam and receiving the threadless mounting bolt of the second mounting bracket, and wherein the lower end of the first mounting beam comprises an elongate slot receiving the respective threadless mounting bolt of the first mounting bracket.
  • B6. The system of any one of paragraphs B-B6, wherein the one or more hanger assemblies comprise a plurality of hangar assemblies spaced apart from each other across an exterior wall of the building.
  • C. A method of mounting facade paneling on a building, the method comprises:
    • fixing a first mounting bracket to a first floor slab of the building and fixing a second mount bracket to a second floor slab of the building, wherein the second floor slab is spaced above the first floor slab;
    • coupling a lower end of a first mounting beam to the first mounting bracket and an upper end of the first mounting beam to the second mounting bracket, such that the first mounting beam extends between the first-story floor slab and the second-story floor slab transverse to the first floor slab and the second floor slab; and
    • coupling one or more facade panels to the first mounting beam.
  • C1. The method of paragraph C, further comprising:
    • actuating a height-adjustment mechanism of the first mounting beam, wherein actuating the height-adjustment mechanism is configured to translate a coupling plate of the first mounting beam up and down relative to a support beam of the first mounting beam, wherein the coupling plate is slidingly coupled to the support beam, and wherein the one or more facade panels are coupled to the coupling plate, such that the one or more facade panels are translated up and down with the coupling plate.
  • C1.1. The method of paragraph C1, wherein actuating the height adjustment mechanism comprises rotating a height-adjustment screw.
  • C2. The method of paragraph C or C1, further comprising:
    • actuating a depth-adjustment mechanism of the first mounting bracket, wherein to adjust a horizontal position of the one or more facade panels relative to the first-story floor slab and the second-story floor slab.
  • D. A system for mounting facade panels on a building, the system comprising:
    • a hanger assembly configured to mount one or more facade panels on a building, the hanger assembly comprising:
      • a first mounting bracket configured to be fixed to a first floor slab of the building and a second mounting bracket configured to be fixed to a second floor slab, wherein the second floor slab is spaced above the first floor slab;
      • a first mounting beam having a lower end coupled to the first mounting bracket and an upper end coupled to the second mounting bracket, wherein the first mounting beam extends between the first floor slab and the second floor slab transverse to the first and second floor slabs, and wherein the first mounting beam is configured to receive the one or more facade panels;
      • a height-adjustment mechanism configured to selectively translate the one or more facade panels up and down relative to the first and second mounting brackets; and
      • a depth-adjustment mechanism coupled to one or both of the first mounting bracket and the second mounting bracket, wherein the depth-adjustment mechanism is configured to selectively translate one or both ends of the first mounting beam outward and inward relative to the respective mounting bracket.
  • D1. The system of paragraph D, wherein the first mounting beam comprises:
    • a support beam including the lower end operatively coupled to the first mounting bracket and the upper end operatively coupled to the second mounting bracket; and
    • a sliding plate coupled to a front side of the support beam, such that the sliding plate is configured to be selectively repositioned relative to the support beam, wherein the sliding plate is configured to receive the one or more facade panels.
  • D1.1. The system of paragraph D1, wherein the support beam includes a slot formed in the front side of the support beam, and wherein the sliding plate includes a rearward extending protrusion configured to be slidingly received within the slot to couple the sliding plate to the support beam.
  • D1.2. The system of paragraph D1 or D1.1, wherein the height-adjustment mechanism is configured to selectively translate the sliding plate up and down relative to the support beam, wherein the one or more facade panels coupled to the sliding plate are translated up and down with the coupling plate.
  • D2. The system of any one of paragraphs D-D1.2, wherein the first mounting bracket and the second mounting bracket each comprise a base plate fixed to the respective floor slab and a pair of parallel plates projecting from the base plate to define a receiving channel, wherein the receiving channel is configured to receive the respective end of the first mounting beam.
  • D3. The system of any one of paragraphs D-D2, further comprising:
    • a third mounting bracket configured to be fixed to a third floor slab spaced above the second floor slab; and
    • a second mounting beam having a second-beam lower end coupled to the second mounting bracket and a second-beam upper end coupled to the third mounting bracket.
  • D3.1. The system of paragraph D3, wherein the depth adjustment mechanism comprises a first depth-adjustment mechanism coupled to the upper end of the first mounting beam, and a second depth adjustment mechanism coupled to the second-beam lower end of the second mounting beam.
  • D3.2. The system of paragraph D3.1, wherein the first depth-adjustment mechanism is configured to selectively translate the upper end of the first mounting beam inward and outward relative to the second mounting bracket, and wherein the second depth-adjustment mechanism is configured to selectively translate the second-beam lower end inward and outward relative to the second mounting bracket.
  • D3.3. The system of paragraph D3.1 or D3.2, wherein the first depth-adjustment mechanism and the second depth-adjustment mechanism are configured to be adjusted independently of each other.
  • D4. The system of any one of paragraphs D-D3.3, further comprising:
  • a respective threadless mounting pin coupling the first mounting bracket to the lower end of the first mounting beam and the second mounting bracket to the upper end of the first mounting beam.
  • D5. The system of any one of paragraphs D-D4, further comprising:
    • a plurality of the hanger assemblies spaced apart from each other across an exterior wall of the building.
  • E. A method of mounting facade paneling on a building, the method comprising:
    • fixing a first mounting bracket to a first floor slab of the building and fixing a second mounting bracket to a second floor slab of the building, wherein the second floor slab is spaced above the first floor slab;
    • coupling a lower end of a first mounting beam to the first mounting bracket and an upper end of the first mounting beam to the second mounting bracket, such that the first mounting beam extends between the first floor slab and the second floor slab transverse to the first floor slab and the second floor slab; and
    • coupling one or more facade panels to the first mounting beam.
  • E1. The method of paragraph E, further comprising:
    • actuating a height-adjustment mechanism of the first mounting beam, wherein the first mounting beam comprises a support beam coupled to the first mounting bracket and the second mounting bracket and a sliding plate slidingly coupled to a front side of the support beam, wherein actuating the height-adjustment mechanism is configured to translate the sliding plate up and down relative to the support beam of the first mounting beam, and wherein the one or more facade panels are coupled to the sliding plate, such that the one or more facade panels are translated up and down with the sliding plate.
  • E1.1. The method of paragraph E1, wherein actuating the height adjustment mechanism comprises rotating a height-adjustment screw operatively coupled to the sliding plate.
  • E2. The method of any one or paragraphs E-E1.1, further comprising:
    • actuating a first depth-adjustment mechanism coupled to the first mounting bracket and the lower end of the first mounting beam, wherein the first depth-adjustment mechanism is configured to selectively translate the lower end of the first mounting beam inward and outward relative to the first mounting bracket.
  • E2.1. The method of paragraph E2, wherein actuating the first depth-adjustment mechanism comprises rotating a depth-adjustment screw operatively coupled to the lower end of the first mounting beam.
  • E3. The method of any one of paragraphs E-E2.1, further comprising:
    • actuating a second depth-adjustment mechanism coupled to the second mounting bracket and the upper end of the first mounting beam, wherein the second depth-adjustment mechanism is configured to selectively translate the upper end of the first mounting beam inward and outward relative to the second mounting bracket.
  • E4. The method of any one of paragraphs E-E3, wherein coupling the lower end of the first mounting beam to the first mounting bracket comprises inserting a threadless mounting pin through a first slot formed in the first mounting bracket and through a second slot formed in the first mounting beam.
  • E5. The method of any one of paragraphs E-E4, wherein fixing the first mounting bracket to the first floor slab includes fixing the mounting bracket to one or more mounting bolts embedded in the floor slab.
  • E6. The method of any one of paragraphs E-E5, further comprising:
    • fixing a third mounting bracket to a third floor slab spaced above the second floor slab; and
    • coupling a second-beam lower end of a second mounting beam to the second mounting bracket and a second-beam upper end of the second mounting beam to the third mounting bracket, such that the second mounting beam extends between the second floor slab and the third floor slab transverse to second and third floor slabs.

Advantages, Features, and Benefits

The different embodiments and examples of the floor-to-floor panel mounting system described herein provide several advantages over known solutions for mounting interior and exterior wall panels on a building. For example, illustrative embodiments and examples described herein allow for panel mounting structures which span between opposing floor slabs of the building and attach to the building at the floor slabs. This ensures that the panel mounting structures do not require specific locations of wall stud members nor the construction of a structure on top of the stud wall or other building substrates to mount the panel mounting structures.

Additionally, and among other benefits, illustrative embodiments and examples described herein provide a multi-directional, post-installation adjustability of wall panels. For example, illustrative panel mounting systems permit depth, height, and angular or tilt adjustment of the panels post installation.

Additionally, and among other benefits, illustrative embodiments and examples described herein provides a coupling mechanism that accommodates for building movement to avoid failures of the exterior wall covering.

Additionally, and among other benefits, illustrative embodiments and examples described herein provide a mounting system that has a heavier load capacity than previous systems.

Additionally, and among other benefits, illustrative embodiments and examples described herein provides a mounting system that extends from floor to floor, such that panels may span the entire distance between floors.

Additionally, and among other benefits, illustrative embodiments and examples described herein allow for a more cost-effective installation process, by allowing a panel mounting system to be installed during construction of a building, rather than retrofitting the building with a panel mounting system.

Additionally, and among other benefits, illustrative embodiments and examples described herein provide a system that allows an installer to skip the time-consuming step of finding anchor points in a wall by only requiring the installer to locate the floor slabs of a building.

Additionally, and among other benefits, illustrative embodiments and examples described herein provide a mounting system capable of larger spans than other more traditional mounting systems.

No known system or device can perform these functions. However, not all embodiments and examples described herein provide the same advantages or the same degree of advantage.

CONCLUSION

The disclosure set forth above may encompass multiple distinct examples with independent utility. Although each of these has been disclosed in its preferred form(s), the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense, because numerous variations are possible. To the extent that section headings are used within this disclosure, such headings are for organizational purposes only. The subject matter of the disclosure includes all novel and nonobvious combinations and subcombinations of the various elements, features, functions, and/or properties disclosed herein. The following claims particularly point out certain combinations and subcombinations regarded as novel and nonobvious. Other combinations and subcombinations of features, functions, elements, and/or properties may be claimed in applications claiming priority from this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.

Claims

1. A system for mounting facade panels on a building, the system comprising: a hanger assembly configured to mount one or more facade panels on a building, the hanger assembly comprising: a first mounting bracket configured to be fixed to a first floor slab of the building and a second mounting bracket configured to be fixed to a second floor slab, wherein the second floor slab is spaced above the first floor slab;a first mounting beam having a lower end coupled to the first mounting bracket and an upper end coupled to the second mounting bracket, wherein the first mounting beam extends between the first floor slab and the second floor slab transverse to the first and second floor slabs, and wherein the first mounting beam is configured to receive the one or more facade panels;a height-adjustment mechanism configured to selectively translate the one or more facade panels up and down relative to the first and second mounting brackets; anda depth-adjustment mechanism coupled to one or both of the first mounting bracket and the second mounting bracket, wherein the depth-adjustment mechanism is configured to selectively translate one or both ends of the first mounting beam outward and inward relative to the respective mounting bracket.

2. The system of claim 1, wherein the first mounting beam comprises: a support beam including the lower end operatively coupled to the first mounting bracket and the upper end operatively coupled to the second mounting bracket; anda sliding plate coupled to a front side of the support beam, such that the sliding plate is configured to be selectively repositioned relative to the support beam, wherein the sliding plate is configured to receive the one or more facade panels.

3. The system of claim 2, wherein the support beam includes a slot formed in the front side of the support beam, and wherein the sliding plate includes a rearward extending protrusion configured to be slidingly received within the slot to couple the sliding plate to the support beam.

4. The system of claim 2, wherein the height-adjustment mechanism is configured to selectively translate the sliding plate up and down relative to the support beam, wherein the one or more facade panels coupled to the sliding plate are translated up and down with the sliding plate.

5. The system of claim 1, wherein the first mounting bracket and the second mounting bracket each comprise a base plate fixed to the respective floor slab and a pair of parallel plates projecting from the base plate to define a receiving channel, wherein the receiving channel is configured to receive the respective end of the first mounting beam.

6. The system of claim 1, further comprising: a third mounting bracket configured to be fixed to a third floor slab spaced above the second floor slab; anda second mounting beam having a second-beam lower end coupled to the second mounting bracket and a second-beam upper end coupled to the third mounting bracket.

7. The system of claim 6, wherein the depth-adjustment mechanism comprises a first depth-adjustment mechanism coupled to the upper end of the first mounting beam, and a second depth-adjustment mechanism coupled to the second-beam lower end of the second mounting beam.

8. The system of claim 7, wherein the first depth-adjustment mechanism is configured to selectively translate the upper end of the first mounting beam inward and outward relative to the second mounting bracket, and wherein the second depth-adjustment mechanism is configured to selectively translate the second-beam lower end inward and outward relative to the second mounting bracket.

9. The system of claim 7, wherein the first depth-adjustment mechanism and the second depth-adjustment mechanism are configured to be adjusted independently of each other.

10. The system of claim 1, further comprising: a respective threadless mounting pin coupling the first mounting bracket to the lower end of the first mounting beam and the second mounting bracket to the upper end of the first mounting beam.

11. The system of claim 1, further comprising: a plurality of the hanger assemblies spaced apart from each other across an exterior wall of the building.

12. A method of mounting facade paneling on a building, the method comprising: fixing a first mounting bracket to a first floor slab of the building and fixing a second mounting bracket to a second floor slab of the building, wherein the second floor slab is spaced above the first floor slab;coupling a lower end of a first mounting beam to the first mounting bracket and an upper end of the first mounting beam to the second mounting bracket, such that the first mounting beam extends between the first floor slab and the second floor slab transverse to the first floor slab and the second floor slab; andcoupling one or more facade panels to the first mounting beam.

13. The method of claim 12, further comprising: actuating a height-adjustment mechanism of the first mounting beam, wherein the first mounting beam comprises a support beam coupled to the first mounting bracket and the second mounting bracket and a sliding plate slidingly coupled to a front side of the support beam, wherein actuating the height-adjustment mechanism is configured to translate the sliding plate up and down relative to the support beam of the first mounting beam, and wherein the one or more facade panels are coupled to the sliding plate, such that the one or more facade panels are translated up and down with the sliding plate.

14. The method of claim 13, wherein actuating the height-adjustment mechanism comprises rotating a height-adjustment screw operatively coupled to the sliding plate.

15. The method of claim 12, further comprising: actuating a first depth-adjustment mechanism coupled to the first mounting bracket and the lower end of the first mounting beam, wherein the first depth-adjustment mechanism is configured to selectively translate the lower end of the first mounting beam inward and outward relative to the first mounting bracket.

16. The method of claim 15, wherein actuating the first depth-adjustment mechanism comprises rotating a depth-adjustment screw operatively coupled to the lower end of the first mounting beam.

17. The method of claim 12, further comprising: actuating a second depth-adjustment mechanism coupled to the second mounting bracket and the upper end of the first mounting beam, wherein the second depth-adjustment mechanism is configured to selectively translate the upper end of the first mounting beam inward and outward relative to the second mounting bracket.

18. The method of claim 12, wherein coupling the lower end of the first mounting beam to the first mounting bracket comprises inserting a threadless mounting pin through a first slot formed in the first mounting bracket and through a second slot formed in the first mounting beam.

19. The method of claim 12, wherein fixing the first mounting bracket to the first floor slab includes fixing the first mounting bracket to one or more mounting bolts embedded in the first floor slab.

20. The method of claim 12, further comprising: fixing a third mounting bracket to a third floor slab spaced above the second floor slab; andcoupling a second-beam lower end of a second mounting beam to the second mounting bracket and a second-beam upper end of the second mounting beam to the third mounting bracket, such that the second mounting beam extends between the second floor slab and the third floor slab transverse to second and third floor slabs.