Patent Grant
8938927
The present invention relates to insulated metal panels and, more particularly, to siding systems in which insulated metal panels are installed running horizontally across wall framing for a building.
There are a wide variety of metal covers that have been used in the construction industry to provide a building's outermost barrier to wind and water. They may be manufactured to resemble wood shake, slate, shingles, clay tiles or other non-metallic cover materials and may be installed on exterior walls or on roofs. Metal covers can provide excellent weather resistance and durability.
One common type of metal covering utilizes insulated metal panels. The panels typically have a relatively thick insulating core sandwiched between thin metal interior and exterior facings. The insulating core most commonly is a rigid foam such as polyisocyanurate, polyurethane, and extruded and expanded polystyrene foams. The metal facing may be made of various metals, such as coated steel and aluminum, and usually is prefinished. They typically are formed by a continuous, foamed-in-place manufacturing process that binds the metal facings to the foam core.
The panels may be installed in any length, but typically are rather elongated, often being installed in lengths up to 40 feet or longer. They commonly will be from 24 to 42 inches wide and from 2 to 6 inches thick. The lateral sides of the panels are provided with profiles so that the panels may be joined along adjacent sides by interlocking seams or joints. When insulated metal panels are used to provide roof covers, the lateral sides of the panels may be configured in various way, for example, to provide a standing seam, high rib, or tongue-in-groove seam between adjacent panels. When they are used as wall siding, however, the lateral sides of insulated metal panels most commonly will have mating profiles which allow adjacent panels to be joined along their sides by a tongue-in-groove joint.
An insulated metal panel siding system will incorporate various flashings, trim pieces, sealants, and other components where the field of a wall terminates, such as at the top and bottom of a wall, corners, and around doors and windows. Even where a building has many intersecting walls, doors, windows, and the like, however, the basic construction of insulated metal panel siding systems over the expanse of the walls is fairly standard. The panels will be mounted on the wall framing of the building or other structure by various clips and fasteners. They most commonly are installed vertically, that is, the length of the panel will run vertically across the wall framing. Insulated metal panels, however, also are installed horizontally, that is, with the length of the panel running horizontally across the wall framing.
Clips typically will be used to secure one side of the insulated metal panel to a frame member. For vertical installations, it usually will be mounted to horizontal frame members, such as a wall girt. When the panels are installed horizontally, they most commonly will be mounted on vertical frame members, such as a post or stud. In either event, clips will be used to secure one side of the panel to a frame member, and the other side of the panel will be joined to an adjacent panel by a tongue-in-groove joint. The abutting side of the adjacent panel will be secured by a clip, thus both sides of the panel are secured to the wall framing.
Such prior art insulated metal panel siding systems are illustrated in
When insulated metal panels are installed horizontally, the panels typically will be installed from the bottom up. That is, a first panel is installed near the base of the wall framing.
As shown in
For example, as seen in
In any event, it will be appreciated that base clip 30 is configured such that the outer, shorter side of clip 30 extends into lower, outer groove 26a in lower profile 24 of lowermost panel 20a. The lower side 24 of panel 20a, therefore, is connected and supported proximate to post 12. The upper side 23 will be secured to post 12, for example, with screws 27 and clips 28 as shown in
Such insulated metal panel siding systems and installations offer significant advantages over other siding systems. Insulated metal panels provide significant structural support and generally reduce the amount of framing required. Large areas also may be covered with relatively few panels, and the panels may be installed with relatively few additional components and fasteners. Installation, therefore, may proceed more quickly and with less labor costs than other siding systems. The various clips and trim pieces typically are fabricated from steel, aluminum, or other metals. Thus, they are strong and lightweight, and may be easily fabricated by roll formers and metal stamps in a variety of configurations to further simplify installation.
When conventional metal base clips are used, however, certain issues may present themselves. For example, once the upper side of a panel is mounted to the wall frame, conventional metal base clips may allow the lower part of the bottom panel to flare out and away from the building frame. That flaring may make it more difficult to seal around the bottom of the panel, and in any event can make the panel appear out of plumb.
Because of the structural integrity of insulated metal panels, the vertical frame members to which the panels are mounted may by relatively widely spaced. For example, in a post and beam frame, the columns may be spaced 4 to 8 feet apart. When the spacing is relatively wide, however, there is a tendency for panels to bow or puff out between the panels as a result of thermal deflection.
When insulated metal panels are installed they also have a visible joint gap. Ideally, the panels are leveled so that the joint gap appears to the eye to be perfectly horizontal. Especially in longer lengths, however, the panels may weigh as much as 250 pounds. The weight and bulk of the panels makes it more difficult to ensure that they are installed on level.
Flashing and sealant beads may be provided between the base clip, the bottom panel, and the wall frame so as to provide a moisture barrier. Typically, however, weep holes are provided in the base clip to allow collected moisture to drip out. Thus, insects in their larval stage, such as the larder beetle (Dermestes lardarius) and other Dermestidae beetles (commonly known as hide beetles) are able to access the foam core of the bottom panel and are known to burrow into the foam. Such burrowing in time will a degrade and weaken the panel. Such problems are particularly acute in poultry, pork, and other animal containment facilities, insofar as the mature beetle may lay eggs in manure. Such insects also may act as vectors transmitting disease to animals sheltered in a building, such as the transmission of salmonella and campylobacter to poultry.
The statements in this section are intended to provide background information related to the invention disclosed and claimed herein. Such information may or may not constitute prior art. It will be appreciated from the foregoing, however, that there remains a need for new and improved siding systems utilizing horizontally installed insulated metal panels and methods for installing insulated metal panels horizontally across a wall frame. Such disadvantages and others inherent in the prior art are addressed by various aspects and embodiments of the subject invention.
The subject invention relates generally to siding systems in which insulated metal panels are installed running horizontally across wall framing for a building and encompasses various embodiments and aspects, some of which are specifically described and illustrated herein. One aspect of the invention provides for an insulated metal panel siding system for a structure which comprises elongated base members and elongated insulated metal panels. The base member is installed along the base of wall framing for the structure and extends across at least two vertical frame members in the wall framing. The base members has a profile running laterally along the upper side thereof. The insulated metal panel is installed on the wall framing running horizontally across the vertical frame members and abutting the base member. The panel has a rigid foam core, an interior metal facing, and an exterior metal facing. The panel also has a profile running laterally along the lower side thereof. The upper profile of the base member and the lower profile of the panel are adapted to allow the base member and the panel to be joined by a tongue-in-groove joint running horizontally across the wall framing.
Other aspects provide such siding systems where the upper profile of the base member covers exposed portions of the foam core in the lower side of the panel. Additional aspects and embodiments provide such siding systems where the base member has a thickness equal to the thickness of the panel and the upper profile of the base member and the lower profile of the panel abut continuously across the profiles.
Another embodiment provides such siding systems where the panel has an upper profile running laterally along the upper side thereof and wherein the upper profile of the panel and the upper profile of the base member are the same.
Yet another aspect and embodiment provides such siding systems comprising a plurality of the panels installed on the wall framing. The panels run horizontally across the wall framing and abut along adjacent sides thereof. Each panel has the lower profile in the lower side thereof and an upper profile in the upper side thereof. The lower and upper panel profiles are adapted to allow adjacent the panels to be joined by tongue-in-groove joints running horizontally across the wall framing between abutting the upper and lower panel sides.
Various other aspects provide such siding systems where the lower and upper panel profiles provide a plurality of tongue-in-groove joints between abutting the upper and lower panel sides. Other aspects provide such siding systems where the upper profile of the base member has at least one tongue and the lower profile of the panel has at least one groove mating with the tongue or where the upper profile of the base member has a pair of tongues and the lower profile of the panel has a pair of grooves mating with the tongues.
Yet other embodiments of the subject invention provide such siding systems where the base member is fabricated from wood, such as treated wood.
Another aspect provides for such siding systems where the tongue-in-groove joint between the base member and the panel is provided with a sealant, such as where the sealant is provided at the top of the tongues in the tongue-in-groove joint.
Still other embodiments provide such siding systems where the base member is mounted on vertical frame members provided in the wall framing by fasteners extending through the base member into the vertical frame members.
Further aspects and embodiments provide such siding systems where the panel is mounted on vertical frame members provided in the wall framing by fasteners extending through a clip and the panel into the vertical frame members.
The subject invention also encompasses methods for installing insulated metal panel siding systems. Such embodiments include methods where insulated metal panels are installed to provide siding for a structure by installing an elongated base member and installing a first insulated metal panel. The base member is installed across vertical frame members in wall framing for the structure at the base thereof and has a profile running laterally along the upper side thereof. The first insulated metal panel is installed across the frame members and above the base member. The panel has a profile running laterally along the lower side thereof. The panel is installed such that the panel runs horizontally across the wall framing with its the lower profile mating with the upper profile of the base member to provide a tongue-in-groove joint between the base member and the first panel.
Other aspects and embodiments provide such methods where the first panel has an upper profile running laterally along the upper side thereof and the method comprises installing a second insulated metal panel across the frame members and above the first panel. The second panel has a lower profile running laterally along the lower side of the second panel. The second panel is installed such that the second panel runs horizontally across the wall framing with its the lower profile mating with the upper profile of the first panel to provide a tongue-in-groove joint between the first panel and the second panel.
Further embodiments provide such methods where the upper profile of the base member covers exposed portions of the foam core in the lower side of the panel.
Another aspect provides such methods where the base member has a thickness equal to the thickness of the panel and the upper profile of the base member and the lower profile of the panel abut continuously across the profiles.
Still other embodiments provide such methods where the upper profile of the first panel and the upper profile of the base member are the same.
Finally, still other aspect and embodiments of the invention will provide siding systems and methods of installing siding systems that will encompass various combinations of such features as will be apparent to workers in the art.
Thus, the present invention in its various aspects and embodiments comprises a combination of features and characteristics that are directed to overcoming various shortcomings of the prior art. The various features and characteristics described above, as well as other features and characteristics, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments and by reference to the appended drawings.
Since the description and drawings that follow are directed to particular embodiments, however, they shall not be understood as limiting the scope of the invention. They are included to provide a better understanding of the invention and the manner in which it may be practiced. The subject invention encompasses other embodiments consistent with the claims set forth herein.
In the drawings and description that follows, like parts are identified by the same reference numerals. The drawing figures are not necessarily to scale. In some drawings certain components that normally would be drawn together are shown with slight spacing so that the separate components may be visualized more easily. Certain features of the embodiments also may be shown exaggerated in scale or in somewhat schematic form and some details of conventional design and construction may not be shown in the interest of clarity and conciseness.
The subject invention relates generally to siding systems, and buildings and other structures incorporating siding systems in which insulated metal panels are installed running horizontally across wall framing for the structure. Broader embodiments of the siding systems comprise an elongated base member that is used to install the lowermost insulated metal panel in a horizontal installation. The base member is installed along the base of wall framing of the building. It extends across at least two vertical frame members in the wall framing, but preferably extends across the expanse of the wall framing. The base member is provided with a profile running laterally along its upper side. The upper profile of the base member and the lower profile of the insulated metal panel are coordinated so that the base member and the panel may be joined by a tongue-in-groove joint running horizontally across the wall framing.
For example, a preferred siding system 10 shown in
As best seen in
Panels 20 are installed horizontally across the array of posts 12 in wall framing 11. By horizontal, it will be understood that panels 20 are installed such that the length of panels 20 extends horizontally across the field of the wall, as opposed to running vertically or up-and-down across the field. Preferably, individual panels 20 are long enough to extend across the entire length of the wall, but the length may be covered by panels abutting at their ends or abutting with other types of siding.
Siding system 10 may be installed across wall frame 11 by first installing an elongated base member, such as base member 40, proximate to the base or lower boundary of wall frame 11. Base member 40 extends across posts 12 in wall frame 11. As will be better appreciated from the description that follows, base member 40 preferably extends continuously along the entire base of wall frame 11. Depending on the length of wall frame 11, however, base member 40 may be installed in separate lengths.
As best appreciated from
As seen best in
Base 40 is adapted to support the lowermost panel 20a and to secure its lower side 24. Thus, upper profile 43 of base member 40 is configured to mate with lower profile 24 of lowermost panel 20a such that base member 40 and panel 20a are joined by a tongue-in-groove joint running horizontally across wall framing 11. More particularly, it will be noted that when mated, base member 40 and panel 20a are joined by pair of tongue-in-groove joints, outer tongue 45a on profile 43 extending into outer groove 26a on lower profile 24 of panel 20a and inner tongue 45b on profile 43 extending into inner groove 26b on lower profile 24 of panel 20a. It will be noted that upper profile 43 of base member 40 preferably is substantially identical to upper profile 23 of panels 20. Lowermost panel 20a, therefore, may be the same as panels 20 installed higher up on the wall.
As shown in
In any event, as appreciated from
The transition areas of the novel siding systems, that is, the areas where the panels abut or terminate into another field or with other features of a structure, such as corners, windows, doors, eaves and the like, may be installed and finished in a manner similar to conventional siding systems. Many such methods of installing and finishing siding systems in transition areas are known. The ends or sides of panels may be attached to frame members in such areas by, e.g., through-panel screws and other fasteners. A variety of conventional clips also may be employed. Conventional trims, flashings, and sealants may be used, and voids in such transitional areas typically will be provided with expanding foam or other insulating materials.
Where fields of siding system 11 intersect at outside or inside corners they may be finished with butt or mitered joints. As illustrated in
It will be appreciated that the base members preferably will provide continuous support along the entire lower side of the lowermost panels in the siding. For example, base member 40 in siding system 10 preferably extends in one or more pieces continuously along the entire base of wall frame 11 and around the base of other walls in the structure. The thickness of base member 40 also is equal, that is, substantially equal to the thickness of panels 20. Thus, the lower portions of siding system 10 have a neat, finished appearance, and upper profile 43 of base member 40 abuts lower profile 24 of panel 20a in a continuous, that is, substantially continuous fashion.
Some play between base member 40 upper profile 43 and panel 20a lower profile 24 is inevitable given manufacturing tolerances. An expansion gap also typically will be provided between the top of tongues 45 and the depth of grooves 26 as is common in tongue-in-groove joints. In this regard, it will be noted that
Otherwise, base member 40 is able to provide tight, substantially continuous support for lowermost panel 20a along its entire length. Lowermost panels 20a, therefore are reinforced and less susceptible to flaring out away from wall framing 11. Panels 20, and especially lowermost panel 20a, also are more resistant to bowing outward between posts 12, even when posts 12 are spaced relatively widely.
It also will be appreciated that the base members may make it easier to install the panels on level. Insulated metal panels, for example, may be quite heavy and unwieldy, and installers may find it difficult to ensure that the lowermost panel does not dip toward one end of the wall or the other. Base member 40, for example, is more easily handled than panels 20a and may be more easily installed on level. Once installed, it is able to provide sufficient support to ensure that panel 20a and the other panels 20 installed above it are on level.
Perhaps more importantly, however, the novel siding systems may provide greater protection against damage from Dermestidae beetles and other insects that may burrow into the foam core of insulated metal panels. That is, insulated metal panels typically are formed by a continuous, foamed-in-place manufacturing process that roll forms the metal facing of the panels. The exterior and interior metal facings wrap partially around and into the profiled panel sides. The metal facings, however, do not extend completely across the panels sides. Portions of the foam core are exposed or are covered by relatively thin plastic films and when installed can be accessed and damaged by certain insects.
For example, and as best appreciated from
Panels 20 and other insulated metal panels which may be used in the novel siding systems typically will have polyisocyanurate, polyurethane, and extruded and expanded polystyrene foam cores. The metal facings typically will be fabricated from coated steel, such as G90 galvanized (A653) steel, and AZ 50 aluminum-zinc alloy coated (A792) steel, and aluminum, in 22 to 26 gauge thicknesses. The metal facings most commonly will be prefinished on both the interior and exterior faces. Exterior finishes include polyvinylidene fluoride coatings such as a 70% Kynar® 500/Hylar® 5000 coating or a silicone modified polyester paint. Interior finishes most typically are a standard polyester paint.
Similarly, the profiles shown in the illustrated panels 20 allow panels 20 to be easily and effectively joined by a tongue-in-groove joint. Panels having other profiles, however, may be used if desired in the novel siding systems to provide a joint between adjacent panels. Many such panels with a variety of profiles are known and commercially available, such as CF Mesa and other panels available from Metl Span, Eco-ficient Classic and other panels available from MBCI, Versawall and other panels available from Centria, and 200 Inverted Rib and other panels available from the Kingspan Group.
The base member of the novel siding systems may be fabricated from various materials. Base member 40, for example, may be fabricated from wood, such a milled Southern Pine, Douglas Fir, or other woods used for dimensional lumber. Preferably, the wood will be treated to enhance its resistance to rot and insect damage. Most commonly, such wood would be pressure treated with various well known copper and boron compounds. Wood treated with creosote and other oil based preservatives, however, may be used as appropriate.
Base members fabricated from wood are preferred. They provide good support and may be manufactured easily and economically by numerous and usually local lumber mills. Other materials, however, may be used. For example, base members may be fabricated from extruded or molded plastics, such as extruded polyvinyl chloride and molded polypropylene. Similarly, they may be fabricated from cast, extruded or formed metal, such as extruded aluminum. Such base members may be solid or may be tubular or channeled to reduce weight and expense. For example, steel and other sheet metals may be roll formed into a generally U-shaped configuration with the base of the “U” being shaped to provide the desired upper profile. Aluminum may be extruded with such profiles.
Novel siding system 10 also has been exemplified in the context of a typical post and beam framing system. It will be appreciated, however, that siding system 10 and other embodiments of the novel siding systems may be installed on buildings having other types of frames, such as balloon framing and platform framing. Such frames may be assembled from dimensional lumber or from light (cold formed) steel members. They also may be installed on heavier steel frames, such as clearspan, modular, or single slope frames.
While this invention has been disclosed and discussed primarily in terms of specific embodiments thereof, it is not intended to be limited thereto. Other modifications and embodiments will be apparent to the worker in the art.
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