Patent Application
20240301685
The present invention relates generally to construction of exterior walls of a building, and more particularly to a prefabricated exterior wall panel assembly for a panelized construction system and a method of assembly of the prefabricated exterior wall panel assembly.
Prefabricated wall panel systems for constructing buildings offer several advantages over alternative stick-built systems, including improved quality control and faster installation with reduced labor. Various solutions have been proposed for panelized construction. For example, US Patent Application Publication No. 2022/0034091 to Kinnunen discloses an arrangement and method for constructing a building that includes prefabricated elements configurable to be connected together and having a metal frame and rigid insulation panels which are attached in the manufacturing phase. US Patent Application Publication No. 2022/0205242 to Malinowski et al. discloses a building system and method utilizing an integrated insulation and a method to construct wall panels having the integrated insulation. US Patent Application Publication No. 2022/0106786 to Niemann discloses a system and methods for extruded aluminum wall panel framing, the framing system panel may be configured to include a window opening, an exterior finish, an insulation, a cladding, a barrier, and a weather resistant barrier. US Patent Application Publication No. 2020/0131761 to Markman et al. discloses a prefabricated wall system that includes a frame that protrudes out from the wall panel and allows the wall panel to connect to the frame of adjacent wall panels. Each wall panel also includes an exterior infill component and an interior structural component. U.S. Pat. No. 10,400,501 to Tatley et al. discloses a window assembly and a prefabricated wall panel that includes a framing with an internal sheathing, an insulation and an external sheathing and forming a window opening in which a window liner is received. U.S. Pat. No. 8,613,181 to Jay et al. discloses an apparatus and methods for installing a penetration, such as a window, in a sheathing assembly. The sheathing assembly includes a barrier layer that is adhered to a body or sheathing layer.
The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is not intended to identify critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented elsewhere herein.
In some aspects, the techniques described herein relate to a prefabricated exterior wall panel that includes a metal stud wall panel frame having a bottom track, a top plate, and vertically extending studs between the bottom track and the top plate. The wall panel may include a window opening. The method of constructing the frame includes compressing the vertically extending studs between the bottom track and the top plate, and welding each of the joints of the vertically extending studs before releasing the compressive force. An exterior sheathing formed from panels of sheathing includes an insulation layer and a weather proofing layer, and if the frame includes a window opening, an opening corresponding to the window opening. A window assembly installed within the window opening includes a glass pane positioned within a frame. A sealant is applied between the panels of sheathing, between the exterior sheathing and the window assembly, and along side edges and a top edge of the exterior sheathing to form a continuous barrier over an exterior surface of the wall panel. A support ledge is positioned at the top of the wall panel, extends laterally from a top portion of the exterior surface of the exterior wall panel, and is configured to support cladding. The support ledge may be connected to a pour stop that extends inward from an interior surface of the exterior wall panel and includes horizontally extending reinforcement bars configured to reinforce a concrete slab. A lintel positioned above the window opening is connected to the frame and configured to support cladding. The support ledge and the lintel are positioned a distance away from the exterior sheathing such that moisture between the exterior sheathing and the cladding is able to drain in an air space therebetween.
Illustrative embodiments of the present disclosure are described in detail below with reference to the attached drawing figures.
The drawing figures do not limit the invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.
The following detailed description references the accompanying drawings that illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized, and changes can be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the invention is defined only by the appended claims, along with the full scope of the equivalents to which such claims are entitled.
In this description, references to “one embodiment,” “an embodiment,” or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment,” “an embodiment,” or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments but is not necessarily included. Thus, the technology can include a variety of combinations and/or integrations of the embodiments described herein.
As used herein, directional references are generally with reference to an orientation of a prefabricated exterior wall panel assembly or exterior wall panel 10 with respect to a building. With reference to
Embodiments disclosed herein describe the exterior wall panel 10 formed with exterior attributes applied to a metal stud wall panel frame or metal stud frame 30 prior to installation and a method of assembly of the exterior wall panel 10 for a panelized construction system used in construction of buildings, including multi-story buildings. The exterior wall panel 10 may be formed as a load bearing wall, a curtain wall or an infill wall. The exterior wall panels 10 are preferably manufactured or constructed by a prefabricator in a factory, the completed exterior wall panels 10 are transported to a construction site stacked horizontally with appropriate dunnage, and the exterior wall panels 10 are installed or positioned vertically to form an exterior wall or façade of a building.
The wall panels 10 are configurable, including the size and shape, to use in buildings having different structural and/or architectural designs.
The frame 30 is comprised of frame members, including a horizontally extending bottom track 54, a horizontally extending top plate or track 56 extending substantially parallel to the bottom track 54, and a plurality of vertical studs 58 extending therebetween. The vertical studs 58 extend substantially perpendicular to the bottom track 54 and top plate 56.
The frame 30 shown in
Each window opening 31 formed in the frame 30 is surrounded by frame members, including a sill 70 and a header 72. The frame members extending along each lateral side of each window opening 31 include at least one king stud 74, dependent upon the size of the opening, and may also include a jack stud (not shown) extending between the sill 70 and the header 72 or bottom track 54. Below the sill 70 and above the header are shortened studs or cripple studs 76. The studs 58, the king studs 74, and the cripple studs 76 are spaced at intervals to at least meet local codes. In a preferred embodiment, spacing of the studs 58, 74 and 76 exceed local codes by being closer than required.
In one embodiment, the header 72 as shown in
Assembly of the frame 30 may be performed using methods and devices known in the art, for example by using c-shaped vertical studs 58 cut or formed with an approximate square cross-section that are secured to the steel bottom track 54, using stud bracing or bridging (not shown) to reinforce the frame members and prevent buckling of the frame members, and by including an upper deflection track to allow for the roof or floor above to deflect without transferring axial loads to the studs 58, 74 and 76. As shown in
The frame 30 is formed from a structural material having sufficient strength and durability properties to meet building codes and support design features, such materials including steel, aluminum, vinyl and other rigid materials known to one skilled in the art. In a preferred embodiment, the frame 30 comprises frame members that are made from steel. The steel frame members are fully or continuously welded at each of the joints to the other steel frame members, including welding the studs 58, 74 and 76 to the bottom track 54 and top plate 56, in a horizontal position while being compressed together on a compression table. All joints of the exterior wall panel 10 may be similarly connected, including the joints of the frame 30 around openings and the joints of other features described below. The preferred method of assembly of the exterior wall panel 10 is described below.
Referring to
The structural sheathing material 88 is rigid and supports the exterior wall panels 10, including strengthening each exterior wall panel 10 to resist forces, such as those from extreme weather conditions or foundational shifting. The structural sheathing material 88 may include one or more of the following: wood-based products such as plywood, oriented strand board, and waferboard; fiberboard; cement board; gypsum-based products; glass mat products, and other foreseeable materials. In a preferred embodiment, glass mat sheathing having a gypsum core and an outer barrier or casing of fiberglass is used. In one embodiment, the structural sheathing material meets the minimum requirements of a fire wall.
The insulating layer 90 and the weather proofing layer 92 are formed from non-structural materials and prevent moisture and air from passing into the sheathing 32 and/or through the exterior wall panel 10 to an interior of the building. The weather proofing layer 92 may be integral with the insulating layer 90, be applied and/or bonded to a surface of the insulating layer 90, or be a separate layer. In addition, the weather proofing layer 92 may be applied and/or bonded to the structural sheathing material 88. Further, the insulating layer 90 and the weatherproofing layer 92 may be integral with the structural sheathing material 88. These non-structural materials may include one or more of the following: plastic; foam; cellulose fiber; paper-faced and/or foil-faced boards, coating materials that are sprayed or painted on a surface, and other materials known to one skilled in the art.
The layers of the sheathing 32 are secured together with mechanical fasteners, adhesives, and/or other connecting or material joining products, those products known to one skilled in the art. The connected layers or layer form panels 100 of the sheathing 32.
The structural and non-structural material members and/or the panels 100 of the sheathing 32 are provided to the prefabricator of the exterior wall panels 10 in standard sizes or may have dimensions that are different than the dimensions of each exterior wall panel 10. As shown in
Each exterior wall panel 10 includes the sealant 34, which may comprise a joint sealing tape and/or a sprayable or spreadable sealing compound, applied on an exterior surface 12 of each wall panel, over seams between sections of panels 100 and over the fasteners extending through the sheathing 32 and connecting the sheathing 32 to the frame 30. Further, the sealant 34 is applied around each window assembly 40 to create a seal between the window assembly 40 and the sheathing 32.
Laterally extending edges between the exterior surface 12 and the interior surface 14 of the exterior wall panels 10 include an edge seal 104 extending therearound, sealing the edges of the sheathing 32. In a preferred embodiment, the edge seal 104 extends along vertically extending edges or side edges 106 and a top edge 108 of each exterior wall panel 10. In the embodiment shown in
It is foreseeable that alternate sealants could be used that perform the same function as sealant 34. As shown in
One or more window assemblies 40 may be installed in each exterior wall panel 10 depending on the design of the building. Each window assembly 40 is secured into the window opening 31 of the frame 30 with mechanical fasteners (not shown) known in the art. Each window assembly 40 includes at least the glass pane 50 secured into the window frame 52, and the window assembly 40 may include other components depending on the function of the window assembly 40. Various types of windows known in the art may be installed depending on desired size, shape, and function. In the preferred embodiment, the window assembly 40 is installed in the exterior wall panel 10 by the prefabricator.
As best seen in
As shown in
As best seen in
Reinforcement rods or bars 168, preferably comprising metal reabar, are connected to the vertical leg 162 of the pour stop 150 and are configured to extend into an edge of the poured concrete slab 62. In the embodiment shown, the rebar forming the reinforcing rods 168 have threaded ends 169 which are threaded into tapped weld studs or threaded receivers 170 welded to the inner surface of the vertical leg 162 of the second section 166 of pour stop 150. The size and spacing of the reinforcement rods 168 is dependent on factors, including the span of the concrete slab 62 and the load carried by the decking panel 60 and concrete slab 62. The rods 168 are horizontally positioned approximately halfway between the upper edge and a lower edge of the vertical leg 162 of the pour stop 150. When concrete is poured onto the decking panel 60 and within the pour stop 150, the rods 168 increase the tensile strength of the cured concrete slab 62 to resist cracking and breaking.
As shown in
The support ledge 158 is configured to support cladding 87 installed on the exterior surface 12. The cladding 87 is installed on the top surface of the horizontal flange 172 and is laid or installed up to the lower surface of the next horizontal flange 172, an opening in an exterior wall panel 10, or another stop. The support ledge 158 is spaced outward from the exterior surface 12 by the mounting tabs 174 such that the cladding 87 is spaced away from the sheathing 32 a distance to provide an air space 176 extending between the cladding 87 and the sheathing 32, allowing moisture that penetrates the cladding 87 to drain away from the exterior wall panel 10. In one embodiment the air space 176 is a space between the cladding 87 and the exterior wall panel 10 of at least one inch. In another embodiment, the air space 176 is at least two inches.
The cladding 87 may be a protective layer that includes insulation and weatherproofing and/or a design element of the building. The cladding 87 may include one or more architectural finishes, such as stone, brick, plastic, timber, metal, concrete, weatherboard, and glass. Depending on the self-supporting characteristics of the cladding 87, the support ledge 158 may be configurable to support two to three stories of installed cladding 87 such that in a multi-story building the support ledge 158 is not required on every exterior wall panel 10 of every floor. For example, bricks may be self-supporting for two to three floors, and therefore, the support ledge 158 may be specified to be installed at the top of the exterior wall panels 10 on every other floor. Installation of the cladding 87 is known to one skilled in the art and may include installation of flashing (not shown), creation of weep holes (not shown), and anchoring of the cladding 87 with anchors (not shown).
In one embodiment, the support ledge 158 is connected to the frame 30. In the embodiment shown in
As shown in
The support ledge 158 is also configurable to support cladding 87 installed above openings, such as in the form of a window edge angle or lintel 180 as shown in
Panel lift clips or pick point tabs (not shown) are connected to the top portion of each exterior wall panel 10. A hole (not shown) extending through each tab allows a hook or clamp (not shown) connected to a lifting apparatus (not shown), such as a hoist or crane, to lift the exterior wall panel 10 into a vertical position and/or lift the exterior wall panel 10 into position for installation. Each tab may be removably connected to the exterior wall panel 10.
During prefabrication other features may be incorporated in the exterior wall panel 10 as required or requested, including installing anchors or vertically extending furring channels (not shown) to maintain the air space 176 between the cladding and the sheathing 32, installing the flashing as appropriate, including above each support ledge 158 to prevent seepage of moisture into the sheathing 32 and into the building, and/or installing other exterior attributes.
Each exterior wall panel 10 is preferably constructed using the following method that includes minimizing racking or torsion of each exterior wall panel 10 during prefabrication and after prefabrication, including during storage, loading and shipping or transportation. The preferred method of assembling a frame 30 for an exterior wall panel 10 includes: using a gauge of steel for frame members, including studs 58, 74 and 76, a bottom track 54, a top plate 56, a sill 70 and a header 72, and using a number of the steel studs 58, 74 and 76 that will reduce a likelihood of torsion as related to dimensions of the exterior wall panel 10, positioning the studs 58 and 74 and components forming the sill 70 and header 72 between the top plate 56 and bottom track 54, compressing the frame 30, and welding all of the joints of the frame 30, including joints between the studs 58 and 74 and the bottom track 54 and top plate 56, while the bottom track 54, top plate 56 and studs 58 and 74 extending therebetween are under compression and before releasing the compressive force. The studs 58 and 74 are compressed between the bottom track 54 and the top plate 56 of the frame 30. The cripple studs 76 may also be compressed between the bottom track 54 and the sill 70 or the top plate 56 and the header 72 and welded. In a preferred embodiment the frame 30 is compressed in a horizontal position using presses on a compression table (not shown). The compression of the frame 30 while applying the weld to the joints during prefabrication creates a weld that is strong enough to prevent the exterior wall panel 10 from racking or twisting. Because of the gauge of the steel, the number of studs 58, 74 and 76, and the strength of the weld, the exterior wall panel 10 is formed into structure in which torsion is greatly reduced.
The method of constructing each exterior wall panel 10 further includes: connecting panels 100 of sheathing 32 to the frame 30 using fasteners or other securement means, removing excess portions of the panels 100 such that the sheathing 32 complements the frame 30, and sealing between the panels 100 of the sheathing 32 and along side edges 106 and a top edge 108 of the sheathing 32.
The method may further include one or more of the following: connecting a pour stop 150 to a support ledge 158, connecting a pour stop 150 or the pour stop 150 connected to the support ledge 158 to the top of the frame 30 prior to installation of the sheathing 32, connecting a lintel above a window opening 31 prior to installation of the sheathing 32, installing and securing a window assembly 40 in the window opening 31, and sealing between the sheathing 32 and the window assembly 40.
A method of installation of the exterior wall panels 10 having an installed window assembly 40, applied sealant 34, and/or a support ledge 158, includes: for each floor, lifting each exterior wall panel 10 into place with a lifting apparatus having hooks connected to tabs on the exterior wall panel 10, securing each exterior wall panel 10 in place by fastening the bottom track 54 to a concrete slab or foundation below and adjacent exterior wall panels 10 to each other using known fasteners, installing and securing decking panels 60, and pouring a concrete slab 62 onto the decking panels 60. Once the concrete sets, the next floor is constructed. After the building is constructed, the method further includes: sealing joints between the exterior wall panels 10 and applying or installing an exterior finish, such as cladding 87 or paint, to the exterior surface 12.
Due to the reduced torsion, the window assembly 40 is able to be installed and the sealant 34 is able to be applied during prefabrication and then the exterior wall panel is able to be stacked flat and loaded in a horizontal position for storage and/or transportation without the exterior wall panel racking or twisting. Breakage or cracking of the glass panes 50 and popping or separation of the sealant 34 during the lifting and installation process is reduced due to the reduction of stresses on the exterior wall panels 10.
Although the invention has been described with reference to the embodiments illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.
| Number | Date | Country | |
|---|---|---|---|
| 63489054 | Mar 2023 | US |
