Patent Application
20210025176
The present disclosure relates generally to the watertightness and continuous insulation structure of resizable insulated wall panel systems. More particularly, the disclosure is an edging and connecting structure of the prefabricated insulated wall panels for exterior insulation finish system.
In today's construction industry, there are two different fundamental approaches to build exterior insulation finish systems of a building, the on-site approach, in which all the required materials for the exterior wall are applied layer by layer on site, and the prefabricated approach, in which the most required materials are prefabricated in factory into individual wall panels so that their on-site applications are comparatively simpler. Comparing to the on-site approach, the prefabricated one has many advantages, such as better job quality, lower labor cost, less material waste and shorter time for application. However, it also has its challenges and constraints, such as substrate dimensional deviation from the blueprint, watertightness and continuous insulation structure at the joint of adjacent prefabricated panels, flatness perfection of assembled panels. The present invented structure is particularly to solve the following problems in the prefabricated approach:
1) Substrate dimensional deviations from the blueprint. Such dimensional deviations require workers to adjust the prefabricated panels by cutting or patching them on-site to fit the actual dimensions of the substrate. Such on-site cuttings usually undermine or damage the system's water barrier structure, or even the building's exterior aesthetics. Therefore, treatment of the cut edges is needed and must be conducted by skillful workers to reassure the system's original structure and the desired decoration. Such treatment will certainly increase the operation cost.
2) Thermal bridges at the joints of panels to break continuous insulation. Such thermal bridges consume more energy and lower the insulation capacity of the insulated wall panel system.
3) Defects on watertightness structure at the joints of panels. The application defects at the joints of adjacent panels will eventually result in water intruding into the system. In the case when a cut-but-unfinished panel fails to be detected but installed, it will certainly cause the malfunction of the entire system.
4) Defects of substrate surface flatness. The flatness defects on the substrate surface usually cause the aesthetics defects or even quality issue when the two adjacent panels are installed upon it. It is more difficult and cost to adjust the flatness of the adjacent prefabricated panels during application.
This invention intends to achieve the following objects in the insulated wall panel systems.
Firstly, it allows the precisely prefabricated panels to be connected to each other by inserting the panel positioning plate between the two grooves at the edge of two adjacent panels so that the plate is tightly embraced by the grooves to accomplish the system watertightness structure at the joint of wall panels.
Secondly, it allows the panel positioning plate to be cut on-site when required during installation to achieve the size tolerance or panel resizable capability.
Thirdly, the surface of the said positioning plate between the two adjacent connected panels can be recessed from the surface of the panels so that it forms a) another seam that can be filled with mortar or sealant to produce a seamless appearance for the panel joint, or b) an architectural fluting that can be coated with the same color and texture as those of the panel to achieve architectural appearance.
Fourthly, the surface of the said positioning plate between the two adjacent panels can also raise from the surface of the panels so that it forms an architectural bossage that can be coated with the same color and texture as those of the panel to achieve architectural appearance.
Fifthly, the said positioning plate can be fastened directly to the panel-supporting frame using drilled honeycomb clips and metal fasteners so that it can mechanically hold the edges of the connected panels against the panel-supporting frame.
Sixthly, the said clips, with pre-drilled honeycomb holes that allows front sealant to connect to the positioning plate through the honeycomb holes, are fastened with metal fasteners to the panel-supporting frame.
Seventhly, in the situation that the grooves between panels need to be created to form architectural flutings on the façade, the insulated panel patch can be added to extend the panel edges. Behind the panel positioning plate, the insulated panel patch is used in this invented system to connect the edges of the two adjacent panels to accomplish the system continuous insulation.
Last, this invention allows the insulated panel patch to be cut on-site when most likely required without damaging or weakening the prefinished coat, watertightness structure and continuous insulation.
U.S. Pat. No. 9,783,993, Inventor: Gleeson; James A. Issued: Oct. 10, 2017
Title: Adjustable building panel support device
An adjustable building panel support device comprising a building panel support element, a support bracket and at least one connector suitable for attaching an insulated building panel to a substrate for constructing an insulated wall section. The building support element and the support bracket are fixable together at a user determinable position by the at least one connector whereby the distance between the building panel support element and the support bracket can be varied to accommodate surface variations that may be present on a substrate surface.
U.S. Pat. No. 9,181,692, Inventor: Callaway; Scott. Issued: Nov. 10, 2015
Title: Covering system for a building substrate
A covering system for a building substrate is disclosed. The covering system comprises at least two panels having two opposite, gutter shaped joints, and a joint linking system comprising a cleat configured to accept the adjacent joints, a compression cap configured to bridge the adjacent joints, means for attaching the compression cap and cleat to the building substrate, and a cover cap configured to lie flush with the panels and conceal the compression cap and the attaching means. When assembled, the covering system forms a watertight seal on and prevents water leakage into the building substrate. Further, the covering system provides hidden fasteners, an internal drainage channel, which removes any moisture that migrates into the system, and joints, which allow for expansion and contraction of the panels during assembly and in the course of environmental changes once installed.
U.S. Pat. No. 8,943,767, Inventor: Lewis; David L. Issued: Feb. 3, 2015
Title: Cover device and cover device kit
A cover device kit includes: a plurality of heat insulation components comprising a lightweight construction material such as synthetic resin foam capable of being transported in a disassembled state and then quickly assembled into a box-shaped heat barrier structure having six sides including an opening on an open side for covering an opening in a floor or wall of a building. Four of the plurality of heat insulation components, each includes two complimentary connections for uniting with two corresponding adjacent heat insulation components of the plurality of heat insulation components when assembled into four sidewalls of the box-shaped heat barrier structure. The cover serves as a fifth heat insulation component and unites with the four components that constitute sidewalls of the box-shaped structure and is situated opposite the opening on the open side.
U.S. Pat. No. 6,505,448, Inventor: Ito; Hiroshi. Issued: Jan. 14, 2003
Title: External wall structure
An external wall structure of enhanced exterior design, which is provided with a decorative plate and can be constructed through a simple supplementary work. This external wall structure comprises a horizontally elongated draining member, which is secured to a furring strip, and a couple of upper and lower siding boards which are coupled with each other with the draining member being interposed therebetween. This external wall structure is featured in that a horizontally elongated decorative plate is mounted, via a plurality of fixtures attached to the draining member, on a joint portion between said couple of upper and lower siding boards, thus covering the joint portion.
U.S. Pat. No. 6,145,257, Inventor: Cappuccio; Anthony. Issued: Nov. 14, 2000
Title: Method and system for forming walls
A method and system for forming walls includes a dual-wall cavity. A stud is formed of an outer flange, middle flange and inner flange arranged in an “E” shape configuration. An outer panel attaches to the outer flange, a middle panel attaches to the middle flange and an inner panel attaches to the inner flange. An outer cavity is formed between the outer panel and the middle panel. The outer cavity can be filled with a filler material for providing structural and insulation features. Thereafter, an inner panel attaches to the inner flange for providing an inner cavity. The inner cavity can be used to house utility materials such as plumbing, air ducts, heating and electrical.
U.S. Pat. No. 5,749,282, Inventor: Brow; Richard A. Issued: May 12, 1998
Title: Building panel with double interlock joint and internal gutter
A building panel particularly adapted for horizontal application. The panel presents inner and outer male connectors at the upper edge of the panel, and complimentary inner and outer female connectors at the lower edge of the panel. Gutter means is provided along the upper edge of the panel intermediate of the male connectors. At the opposite ends of the panel, the outer facing sheet presents inturned end portions. Beyond the inturned end portions the foam core and edges of the inner facing sheets are exposed. In a wall structure assembled from a plurality of the panels, horizontal joints between panels and vertical joints between the panel ends are presented. Gasket means is presented in the vertical joint and is configured so as to provide vertically extending discharge channels communicating with the gutter means. Liquids bypassing the outer seals at the joints collects in the gutter means and is directed to the vertical channels for discharge.
U.S. Pat. No. 5,313,751, Inventor: Wittier; Waldemar E. Issued: May 24, 1994
Title: Interlocking structural members with edge connectors
An edge connector for connecting structural members at their adjacent edges is disclosed, including a base extending transversely between its edges, a support wall integral with the base and extending away from the base on one side thereof, the support wall extending generally parallel to the base edges and being positioned between the transverse center of the base and one edge; and a tongue integrally connected at one end to the support wall, extending from the support wall to a free end thereof; and spaced away from the base and positioned between the transverse center of the base and the other edge of the base on the side of the center opposite the one base edge, the tongue and the base defining a recess therebetween to receive the tongue of a mating connector.
U.S. Pat. No. 4,551,958, Inventor: Reneault; Patrick, Issued: Nov. 12, 1985
Title: Exterior insulating element and cladding employing such elements
The insulating element is formed by a rectangular panel composed of insulating material, such as extruded polystyrene foam whose edges include a longitudinal groove forming a rabbet or a center groove. A pasty coating containing mineral particles covers one of the sides of the panel and a flat sealing element is formed on two adjacent edges of the element and permits a rapid and simple assembly of the element with two other respectively juxtaposed and superimposed elements. This sealing element maintains the edges of the elements spaced apart on the outer side of the assembly but closes in a watertight manner the side facing the wall to be insulated.
U.S. Pat. No. 4,077,171, Inventor: Simpson; Harold G., Issued: Mar. 7, 1978
Title: Prefabricated watertight structural system
A prefabricated structural system including a support frame and prefabricated panels having strength sufficient to bridge spaced support beams under the panel is disclosed. Each panel includes a sheet metal support subpanel having corrugations, a thin flat metal sheet as a top surface, and a layer of insulating foam filling the space therebetween. A Hypalon membrane is intimately and continuously bonded to the thin, flat metal sheet and has Hypalon fasteners disposed along each edge of the Hypalon sheet and connected to the Hypalon sheet by flexible flaps. The panels are disposed in a continuous array and fastener halves are joined and the corners sealed to provide a continuous Hypalon membrane unpenetrated by fastener screws above the array of panels. A flashing system is disclosed which continues the Hypalon membrane from the panel array up adjacent parapet walls and building walls and accessories extending above the roof deck and over the edge of the roof deck to the outside of underlying walls to provide a watertight roof structure. The flashing system includes plain and box fascia systems including a box gutter system, parapet flashing, all corner and end transitions for these systems, penetration flashings for vents, pipes, deck drains and curbs.
The prior invention in U.S. Pat. No. 9,783,993 discloses an adjustable supporting structure for wall panels that can accommodate the surface variations of wall substrate without addressing the concerns caused by panel cutting such as watertightness and insulation continuity. The prior arts in U.S. Pat. Nos. 9,181,692, and 8,943,767 introduce the grooved panel edging to accomplish easy assembly and disassembly of the panels, watertight seal, and heat insulation at the panel joints. But both of the said arts are specifically design for the building covering systems, without addressing the watertight and resizing issues of the horizontal wall panel joints. And the art invented in U.S. Pat. No. 6,505,448 provides a structure that only cover the horizontal joints between the upper and lower panels using an elongated decorative plate while the prior art structure in U.S. Pat. No. 6,145,257 discloses an E-shape panel connector to form cavity between outer layer and inner layer panels. None of these two arts address the panel resizing concerns. Although the art solution in U.S. Pat. No. 5,313,751 addresses the issue of interlocking of two adjacent panels, and the art solution in U.S. Pat. No. 5,749,282 addresses for the issue of water infiltration at adjacent panel joint, none of these structures is successful to solve the issue of inevitable on-site panel cutting or patching to fit the substrate size deviations and tolerance while still being able to remain the continuous insulation and watertightness capabilities after panel edges are cut. The art introduced in U.S. Pat. No. 4,551,958 discloses a structure to solve the water condensation and vapor penetration issue by forming a groove on pane vertical edges as well as horizontal edges. But the structure fails to support the prefabricated panel on-site resizing feature. The art in U.S. Pat. No. 4,077,171 provides a solution to the watertight issue to the roof panel joints. However, such art structure cannot be used in the vertical wall panel joints as this invention does.
A primary object of the present invention is to provide a resizable wall panel structure for the prefabricated wall panels, wherein the said panel enables itself to be cut or patched to fit the actual installation size without damaging the prefabricated watertightness layer at the said wall panel joint.
Another object of the present invention is to provide a resizable wall panel structure for the prefabricated wall panels, wherein the said panel enables itself to be cut or patched to fit the actual installation size without damaging the prefabricated continuous insulation capability at the said wall panel joint.
Yet another object of the present invention is to provide an interlocking wall panel structure for the prefabricated wall panels, wherein the said panels are interlocked with a prefabricated but resizable panel positioning plate that can be directly fastened to the wall panel's supporting frame using metal fasteners without damaging the watertightness capability at the said wall panel joint.
Yet another object of the present invention is to provide an interlocking wall panel structure for the prefabricated wall panels, wherein the said panels are interlocked with a prefabricated but resizable panel positioning plate, and wherein the said panel joint is patched with a prefabricated but resizable panel patch without damaging the prefabricated continuous insulation capability at the said wall panel joint.
Yet another object of the present invention is to provide an attachment structure for the prefabricated wall panels at the panel patched joints, wherein the said panels are attached to the wall structure with the positioning plate and concealed pre-drilled honeycomb clips on which there are many predrilled holes to allow the sealants to connect the positioning plate through the holes.
The present invention overcomes the shortcomings of the prior art by providing a structure that builds a prefabricated wall panel edge into two areas, an outer edge area that can be cut and patched on the job site to accomplish insulated panel continuous insulation, and an inner edge area that can be patched with resizable prefabricated and pre-coated plate to accomplish fagade aesthetics and watertightness capability.
In the drawings,
Panel
The prefabricated insulated wall panel basically comprises four layers: the finish coat layer for aesthetic decoration, the mesh reinforced base coat layer for impact and scratch resistance and water barrier performance, the insulation core layer for thermal performance, and the backer layer for the panel to perform better with adhesive materials behind it to achieve tensile resistance. The present disclosure consists of the prefabricated grooves, one at each of the two edges, bottom one and top one of a panel, in the prefabricated insulated wall panel system, wherein the panel positioning plate, and the insulated panel patch if required, connect the two adjacent panels.
Panel Edge
Each edge of the panel consists of two areas, the inner edge area, covered with mesh reinforced base coat that enables watertightness structure, and the outer edge area, extending out from the inner edge area, exposed to the insulation material that enables continuous insulation structure and allows it to be cut or patched without damaging the inner edge area. At the panel bottom edge, as well as top edge, there forms a groove in the inner edge area to embrace the panel positioning plate for watertightness capability as well as aesthetic purpose. In the inner edge area of panel left or right edge, no groove is formed, the outer edge area insulation material extends out so as to connect directly to the one of adjacent panel while the inner edge areas between the adjacent panels are grouted and sealed with mortar and sealant.
Panel Edge Groove
In the present disclosure, the edge groove is formed, only in the inner edge area at the bottom and top edges, in the inner edge area that is covered with mesh reinforced base coat in order to work closely with the compatible material of the panel positioning plate to accomplish the watertightness structure. The width of the edge groove is premade precisely to fit the width of the panel positioning plate so that the groove can embrace the plate tightly.
Panel Positioning Plate
When the panel is installed and its size needs to be tailored, the outer edge area of panel can be cut or patched to meet the substrate dimensional requirements. At the same time, the panel positioning plate and the insulated panel patch may also need to be resized accordingly. The material of the said plate must work compatibly with the material of the panel base coat layer, and the thickness of the plate must work closely with the thickness of premade panel edge grooves.
Decorative Panel Fluting and Bossage
When two adjacent panels embrace the panel positioning plate of which the height is more than twice of the depth of the groove, the three pieces form a panel fluting at the surface of the wall. However, additional premade raised line can also be created and finish-coated on the front side of the panel positioning plate to achieve certain architectural bossage effect.
Panel Clips and Clip Fasteners
The panel clips are fastened directly to the supporting frame using metal clip fasteners so that it mechanically holds the panel edges, panel patch if any, to the panel-supporting frame. The pre-drilled honeycomb holes across the plate allow the watertightness sealant to connect to the panel positioning plate or to the panel's finish coat layer.
Insulated Panel Patch
The thickness of the insulated panel patch should be made exactly the same as the thickness of the outer edge area of panel, however, its insulation material can be different. The said patch will be used to connect the panels only when the panel positioning plate is used for the architecture fluting or bossage effect. The insulated panel patch is also used to achieve continuous insulation as well as the architectural fluting or bossage effect.
The present invention relates to a prefabricated insulated wall panel system with a resizable structure that can readily meet the substrate dimensional requirements and variance, such as on-site dimensional deviation from the shop drawing, by enabling the prefabricated panels to be cut or patched on the job site without damaging the watertightness structure as well as the continuous insulation structure of the system.
The present invention consists of the structure of the prefabricated insulated wall panels, the panel positioning plate, and insulated panel patch if necessary, that connects the two adjacent panels. The said prefabricated insulated wall panel comprises four layers: the finish coat layer for aesthetic decoration, the mesh reinforced base coat layer for impact and scratch resistance and water barrier performance, the insulation core layer for thermal performance, and the backer layer for the panel to perform better with adhesive materials behind it to achieve tensile resistance.
The present invention discloses the structure of continuous insulation and watertightness capabilities at the joint of two adjacent insulated wall panels. On the top and bottom edge of the panel, there is a premade groove that can tightly embrace the panel positioning plate, which can be fastened through mechanical fasteners directly to the substrate wall frames. In the case of the panel insulated patch is used, the height of the insulated patch plus total depths of the two grooves on the connected panel edges shall exactly match the height of the plate.
The structure accomplishes the panel system's sizeable but watertightness capability through the panel premade grooves, the resizable plate and resizable outer edge on top or bottom edge of panel. The plugged-in positioning plate, functioning as a panel-to-panel connector and interlocker, embraced tightly by the grooves on each edge of the panels, can also be resized in its own measurement if necessary. The said plate is plugged in the grooves to interlock two adjacent insulated wall panels and to accomplish watertightness structure at joints of the panels. The said plate also functions as a panel joint control device to assure the precise space between two adjacent panels, to enable the easy and accurate panel installation.
