Patent Application
20090249718
This invention relates generally to the construction field and, more particularly to a corner panel for a veneer wall panel system and a method of mounting that corner panel to an underlying support structure whereby any corner stresses between the corner panel and the underlying support structure are decoupled.
Prefabricated or cast veneer wall panels have been developed as a quick and efficient way to provide a masonry appearance for a building while simplifying construction and lowering construction cost. The design elements of prefabricated wall panels typically simulate brick, stone, tile, and other masonry building components or materials commonly used in the construction of buildings. Examples of prefabricated wall panels are disclosed in, for example, U.S. Pat. No. 1,592,591 to Amele; U.S. Pat. No. 4,659,055 to Hardt; U.S. Pat. No. 3,426,490 to Taylor; U.S. Pat. No. 4,644,719 to Salazar; and U.S. Pat. No. 3,740,910 to Taylor et al.
It is also known in the art to provide specialized corner panels for forming outside building corners in cast veneer wall panel systems. Examples of corner panels are disclosed in the Taylor, Taylor et al and Hardt patents mentioned above. Such corner panels include two sections extending in different planes that define an included angle of 90 degrees. In the past, such corner panels have been anchored to the underlying support structure along both sections of the corner panel, that is, on both sides of the corner defined by the underlying support structure. Where the corner angle (as defined by the corner panel) and the corner angle (as defined by the underlying support structure) do not perfectly match and the corner panel is subsequently attached or mounted to the underlying support structure, such a mounting arrangement or approach causes stresses to build in the corner panel and/or the underlying support structure, which can lead to premature failure over time and a reduced service life for the veneer wall panel system.
The present invention relates to a new and improved corner panel and a method of mounting that corner panel that decouples the stresses between the corner panel and the underlying support structure. By eliminating these stresses, the integrity and service life of a wall panel system are significantly enhanced.
In accordance with the purposes of the present invention as described herein, an improved corner panel is provided for a veneer wall panel system. The corner panel comprises a body including a fastener section extending in a first plane and a fastenerless section extending in a second plane, wherein said first plane and said second plane define an included angle A. The body of the corner panel includes a facing and a backer.
The facing may be made from a cast material selected from a group consisting of concrete, reinforced concrete, gypsum, reinforced cementitious material and mixtures thereof. The facing includes at least one design element. In a typical embodiment, the facing includes only one design element. That design element is selected from a group of possible design element images consisting of a brick, a stone, and a tile.
The backer is made from a material selected from a group consisting of metal, plastic, composite, steel, corrosion-resistant steel, aluminum, stainless steel, zinc, copper and combinations thereof. The corner angle A defined by the two sections of the body may be substantially any angle desired. Typically, the corner angle A is between about 90 to about 120 degrees. For most applications the corner angle A is about 90 degrees.
Further describing the invention, the fastener section includes a projecting hem. In one embodiment, the fastener section includes a first hem projecting from a first edge of a fastener section and a second hem projecting from a second edge of the fastener section. The first hem and second hem may project in opposite directions. In addition fasteners are received and held in the first and second hems to secure the panel to the underlying support structure.
In accordance with still an additional aspect of the present invention, a plurality of dimples may be provided projecting from the backer away from the facing. These dimples serve to provide a drainage space between the corner panel and the underlying support structure. In addition, it should be appreciated that the corner panel is reversible, that is, the corner panel can be used to form left handed or right handed corners.
In accordance with yet another aspect of the present invention, a method is provided of securing a corner panel of a veneer wall panel system to a corner of an underlying support structure. The method comprises the step of positioning the corner panel on the corner of the underlying support structure so that a first section of the corner panel extends along a first portion of the support structure extending away from the corner in a first direction and a second section of the corner panel extends along a second portion of the support structure extending away from the corner in a second direction. In addition, the method includes the steps of fastening the corner panel to the support structure only along the first section of the corner panel and the maintaining of the second section free of any fasteners that would fasten the wall panel to the underlying support structure. By mounting the corner panel to the support structure in this way, the corner panel may accommodate imperfections in a corner angle formed by the underlying support structure, while decoupling any corner stresses between the corner panel and the underlying support structure.
In the following description there is shown and described several different embodiments of the invention, simply by way of illustration of some of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the present invention and together with the description serve to explain certain principles of the invention. In the drawings:
Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.
Reference is now made to
The backer 14 may be made from a material selected from a group consisting of metal, plastic, composite, steel, corrosion-resistant steel, aluminum, stainless steel, zinc, copper, and combinations thereof. The corrosion-resistant steel may take any number of forms, including but not limited to galvanized, galvanneal, GAVALUME brand, tin coating, chromium coating, nickel coating phosphorous coating, magnesium coating, copper coating, weathering steels (i.e., alloys of steel with small additions of copper, aluminum, nickel and/or phosphorous), polymer coatings, paint, and combinations thereof.
Polymer materials useful for making of the backer 14 includes various thermoplastic and thermoset resins, including but not limited to polyolefins, polyesters, polyvinyl chloride, polypropylene, polyethylene, polyamide, epoxy, vinyl ester, acrylic, polystyrene, ABS, melamine, and mixtures thereof. Composite materials used to make the backer 14 include a reinforcing material and a matrix binder. Appropriate reinforcing materials useful in the present invention can include glass fibers, natural fibers, mineral fibers, basalt fibers, carbon fibers, kenaf fibers, jutte fibers, hemp fibers, E-glass fibers, C-glass fibers, R-glass fibers, S-glass fibers, ECR-glass fibers, AR-glass fibers, and mixtures thereof. It should be appreciated, that substantially any type of glass fiber may be used for reinforcement fibers. Glass fibers appropriate for use in the present invention may be loose chopped strand or glass mat and include those available under the trademarks ADVANTEX. Matrix binders useful for this purpose can include polyolefins, polyesters, polyvinyl chloride, polypropylene, polyethylene, polyamide, epoxy, vinyl ester, and mixtures therefore.
The facing 12 and backer 14 are connected together by any appropriate manner known in the art including but not limited to embedding a portion of the backer 14 in the cast material of the facing 12.
The body of the corner panel 10 comprises the facing 12 and the backer 14. The body also includes a first or fastener section 16 extending in a first plane P1 and a second or fastenerless section 18 extending in a second plane P2. The first plane P1 and the second plane P2 (i.e., the first section 16 and second section 18 respectfully) of the corner panel 10 define an included corner angle A. In one embodiment the corner angle A may be substantially any angle, but is typically between about 90 to about 120 degrees and in another embodiment typically about 90 degrees.
In the illustrated embodiment, the included corner angle is 90 degrees and the facing 12 forms a single design element. In the illustrated embodiment that design element has the appearance of a single brick. It should be appreciated, that the design element may take other forms, such as stone or tile. In fact, the design element may simulate substantially any masonry material known to be used in the art. The corner panel 10 is provided for a cast veneer wall panel system of the type used as a wall cladding for a building. Further applications can include the construction of a fireplace surround or an outdoor living component, such as a decorative wall or grill surround. The illustrated corner panel 10 simulates a single design element or brick; it should be appreciated that the corner panel could simulate more than one design element. Such a corner panel would typically include a mortar field for receiving and holding mortar that outlines the design elements to provide the desired masonry appearance.
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More specifically, reference is made to
Summarizing, the corner panel 10 is only connected to the underlying support structures S along the hems 22, 26 projecting from the fastener section 16. The fastenerless section remains free floating over the underlying support structure. In addition, the corner panel 10 is not directly connected or fastened to any other veneer wall panel above it, below it, or at either end; this minimizes the stress placed upon the corner panel 10. For purposes of aesthetics, mortar is used to fill any gap between the corner panel 10 and the adjacent panels. It should be appreciated that mortar is weaker than the corner panel 10 and, accordingly, the mortar will crack due to any building movement or stress before the corner panel 10 will be damaged. Advantageously, cracked mortar is a relatively simple and inexpensive repair. Thus, an aesthetic appearance is achieved while maintenance costs are controlled.
The foregoing description of the preferred embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims in their fair and broad interpretation in any way.
