Patent Application
20240167271
The apparatus and method disclosed herein relates to a wall panel and wall construction for a building.
In building construction, it is common to attach exterior wall panels to supportive building structures such as steel, concrete or masonry pillars or slab or floor edges. This is sometimes referred to as a curtain wall-type construction.
In this type of building construction, the exterior wall panels when assembled into a wall structure, must provide an air vapour barrier between the interior and exterior of the building. As will be appreciated, an air vapour barrier is a barrier that controls water vapour diffusion into the wall structure. The air vapour barrier must provide a substantially continuous barrier from panel to panel across the entire wall structure.
Previous curtain wall systems used a type of gasket joint for offering a panel-to-panel seal for the air vapour barrier. The gasket joint includes a tongue edge on one panel that fits into an edge-wise groove on an adjacent panel. An elastomeric gasket is in the depth of the groove and creates a seal with the tongue edge. However, because these gaskets were recessed in the depth of the joint, their proper seating and sealing could not be adequately inspected and verified during construction. Thus, an unsealed gasket, and therefore a defective air vapour barrier, could not be identified until after the wall was fully constructed, for example when the building was in use.
A wall panel unit is required that permits better inspection and verification of the air vapour barrier panel-to-panel seal.
Therefore in accordance with a broad aspect of the invention, there is provided a wall panel unit comprising: a plurality of studs; a sheet of sheet material mounted on a rear facing side to the plurality of studs, the sheet material including perimeter edges and a perimeter portion of the sheet material extending beyond the plurality of studs to define a perimeter border on the rear facing side; a supportive edging on the perimeter edges of the sheet material and coupled to the studs; a layer of air vapour barrier membrane on a front facing side of the sheet of material, the layer of air vapour barrier membrane wrapped around the perimeter edges being exposed on the perimeter portion; and at least one of: a side edge flashing and a lower edge flashing.
According to another broad, exemplary aspect, there is provided a building exterior wall comprising: a first wall panel unit comprising a sheet of sheet material and a layer of air vapour barrier membrane on a front facing side of the sheet of sheet material, the layer of air vapour barrier membrane wrapped around the perimeter edges and forming a first border of membrane exposed on a perimeter portion of the first sheet of sheet material's rear facing side; a second wall panel unit comprising a sheet of sheet material and a layer of air vapour barrier membrane on a front facing side of the sheet of sheet material, the layer of air vapour barrier membrane wrapped around the perimeter edges and forming a second border of membrane exposed on a perimeter portion of the second sheet of sheet material's rear facing side, the second wall panel unit spaced from the first wall panel unit by a gap; and an air vapour barrier membrane strip at the gap, where a first lengthwise edge of the strip is sealed against the first border and an opposite, second lengthwise edge of the strip is sealed against the second border.
According to another broad, exemplary aspect, there is provided a method for constructing a wall for a building structure, the method comprising: installing a first wall panel unit comprising a sheet of sheet material and a layer of air vapour barrier membrane on a front facing side of the sheet of sheet material, the layer of air vapour barrier membrane wrapped around the perimeter edges and forming a first border of membrane exposed on a perimeter portion of the first sheet of sheet material's rear facing side; installing a second wall panel unit comprising a sheet of sheet material and a layer of air vapour barrier membrane on a front facing side of the sheet of sheet material, the layer of air vapour barrier membrane wrapped around the perimeter edges and forming a second border of membrane exposed on a perimeter portion of the second sheet of sheet material's rear facing side, the second wall panel unit spaced from the first wall panel unit to define a gap between them; and, installing an air vapour barrier membrane strip to span the gap, where installing includes sealing a first lengthwise edge of the strip against the first border and sealing an opposite, second lengthwise edge of the strip against the second border.
The above simplified summary of example aspects serves to provide a basic understanding of the present disclosure. This summary is not an extensive overview of all contemplated aspects, and is intended to neither identify key or critical elements of all aspects nor delineate the scope of any or all aspects of the present disclosure. Its sole purpose is to present one or more aspects in a simplified form as a prelude to the more detailed description of the disclosure that follows. To the accomplishment of the foregoing, the one or more aspects of the present disclosure include the features described and exemplary pointed out in the claims.
The accompanying drawings, which are incorporated into and form a part of this specification, illustrate one or more example aspects of the present disclosure and, together with the detailed description, serve to explain their principles and implementations.
Various aspects of the invention are now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to promote a thorough understanding of one or more aspects of the invention. It may be evident in some or all instances, however, that any aspects described below can be practiced without adopting the specific design details described below. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate description of one or more aspects. The following presents a simplified summary of one or more aspects of the invention in order to provide a basic understanding thereof.
Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
A wall panel unit 14 includes a sheet of sheet material 18 mounted on a plurality of studs 20, a supportive edging 22 on the perimeter edges of the sheet material, a layer of air vapour barrier membrane 26 and at least one of side edge flashing 30 and lower edge flashing 32.
Sheet material 18 is any sheet of material such as drywall (i.e. exterior, but could be interior), wood (i.e. such as plywood, durable particle board or MDF) or metal. In one embodiment, sheet material 18 is exterior grade drywall. Sheet material 18 forms the main planar, structural expanse of the unit. The sheet material has side edges including, in a typical rectangular configuration, an upper edge 18a, a lower edge 18b and side edges 18c, which extend between the upper and lower edges. Of course, the sheet material also has front and rear facing planar surfaces. There may be openings in the sheet material for glazing units, doors, services or other interior to exterior access points.
Studs 20 are coupled to the sheet material 18 on the sheet material's rear facing surface. There may be studs extending vertically and horizontally. Studs 20 include edgewise studs 20a that are at the outer edge of the stud assembly for each panel. In this panel, edgewise studs 20a are spaced back from upper edge 18a, lower edge 18b and side edges 18c of the sheet material. This spacing creates a perimeter 18′ of the rear facing planar surface of the sheet material that is exposed. In particular, this perimeter 18′ is a flange of the sheet material that extends out beyond studs 20 including the edgewise studs. Perimeter 18′ is exposed and overhanging beyond the studs 20 on the rear facing surface of the sheet material.
Supportive edging 22 extends around the perimeter edges 18a, 18b and 18c of the sheet material. The supportive edging extends around substantially the entire perimeter of the sheet material and thereby frames the sheet material. Supportive edging 22 supports the sheet material at its edges, similar to a frame. Edging 22 protects the edges from damage due to impacts and acts as a coupling structure through which studs are connected to the sheet material, whereby the studs are coupled to the supportive edging which is in turn connected to the sheet material. In one embodiment, the supportive edging includes a channel-type structure, such as formed of durable metal or plastic. An elongate channel is in particular defined between two side planar webs 22a, 22b spanned by an end wall 22c. An edge 18a, 18b, 18c of the sheet material resides in the elongate channel of the supportive edging. In so doing, side planar web 22a of the supportive edging lays over a portion of the front facing surface of the sheet material, and web 22b lays over a portion of the rear facing surface of the sheet material, adjacent its edge. Supportive edging 22 can be, for example, a J-channel where front side planar web 22a is shorter than rear side planar web 22b. In one embodiment, the side planar web on the rear side, web 22b, includes a protruding flange 22d that projects away from the channel. Protruding flange 22d can serve as the coupling structure where edging is coupled to studs, such as by use of fasteners.
Air vapour barrier membrane 26 overlies the front facing planar surface of sheet material 18. The air vapour barrier membrane is further wrapped around the perimeter edges 18a, 18b and 18c. In particular, air vapour barrier member 26 is folded from the front facing planar surface of sheet material 18, around the edge such that the member overlies a portion of the rear facing planar surface of the sheet material. That member 26 is then terminated at a terminal edge 26′ on the rear facing planar surface. As such air vapour barrier membrane 26 is substantially continuous across the front facing planar surface, around the edges and on a border adjacent the perimeter edges of the rear facing planar side. The border formed by membrane 26 adjacent the perimeter edges 18a, 18b, 18c on the rear facing side is 2-5 inches (5-10 cm) from the sheet material edge and the terminal edge 26′ of the membrane.
In one embodiment, the air vapour barrier membrane 26 is wrapped over, for example outwardly of, supportive edging 22. As such, the supportive edging is positioned between the sheet material and the air vapour barrier membrane. In one embodiment, the air vapour barrier overlies front side planar web 22a, extends across end wall 22c and the terminal edge 26′ of the air vapour barrier membrane is secured onto the exposed surface of rear side planar web 22b adjacent the protruding flange 20d. As such, the air vapour barrier border and terminal edge 26′ is visible and accessible on the rear facing surface of the wall panel unit.
Membrane 26 is adhered to the sheet material 18 and edging 22. In one embodiment, the membrane is self-adhered to the unit. The entire inward surface of the membrane may have an adhesive coating such that the air vapour barrier membrane can be self-adhered over substantially its entire back side where it contacts the sheet material 18, edging 22, etc.
If there are glazing or other openings in the sheet material 18, the air vapour barrier membrane is terminated in an appropriate matter at the openings.
Air vapour barrier membrane 26 is substantially vapour and air impermeable. The membrane may be constructed of a resilient, such as elastomeric, polymer, such as rubber or plastic. The membrane may be a rubber or polymeric film.
Wall panel unit 14 also includes at least one of: side edge flashing 30 and lower edge flashing 32. Side edge flashing 30 and lower edge flashing 32 are each attached on the front facing planar surface of the sheet material over, for example outwardly of, the air vapour barrier membrane 26.
If present, the side edge flashing 30 is attached along one or both of the side edges 18c of the sheet material. The side edge flashing is elongate and extends along the length of the side edge on which it is attached. The side edge flashing has two parallel elongate sides. One of the elongate sides is secured to the front facing planar surface of sheet material 18 and the opposite elongate side extends laterally beyond the side edge 18c of the sheet material. Therefore, side edge flashing 30 extends out laterally from and beyond the side edge of the sheet material. The side edge flashing may take various forms, but extends generally in plane or in a parallel plane with the front facing planar surface of the sheet material.
The lower edge flashing 32, if present, is attached along the lower edge 18b of the sheet material. The lower edge flashing is elongate and extends along the length of the lower edge. The lower edge flashing has two parallel elongate sides. One of the elongate sides is secured to the front facing planar surface of sheet material 18 and the opposite elongate side extends laterally beyond the lower edge 18b. Therefore, lower edge flashing 32 extends downwardly from and beyond the lower edge of the sheet material. The lower edge flashing may be shaped in various ways, For example, the lower downwardly projecting side can generally extend in plane or in a parallel plane with the front facing planar surface of the sheet material, can define protruding lip 32a.
The wall panel unit 14 may also include a second membrane 36 over the front facing planar surface of the sheet material 18. The second membrane is positioned outwardly of the air vapour barrier, such that the air vapour barrier is located between the sheet material and the second membrane. Second membrane 36 is located on the sheet material or lapped on flashings to shed exterior moisture. Second membrane 36 can also be a resilient, elastomeric film applied by adhesives.
Each wall unit may include further materials on the front facing side, such as insulation, wall cladding, etc. Insulation 38, for example, installed over the air vapour barrier membrane 26 is illustrated in
A wall 10 is constructed with a plurality of the wall panel units 14 installed side by side and one above the other, as shown in
Gaps G1 and G2 accommodate floor slab deflection and inter-story drift, such as during seismic events, so the sheets of sheet material in the wall can move without contacting each other. Gaps G1, G2 can each be 1-3 inches (2.5-7.5 cm) across.
To complete the air vapour barrier for the building wall, air vapour barrier membrane strips 40 are installed across the gaps G1, G2. The membrane strips are solid strips of air vapour barrier membrane and are installed to extend from rear facing planar surface to rear facing planar surface of adjacent sheet materials. Membrane strips 40 each are coupled on one elongate side to the air vapour barrier membrane 26 on the perimeter 18′ of one panel and are connected on the other elongate side to the air vapour barrier membrane 26 on an immediately adjacent, horizontally or vertically-spaced, panel. There is a seal between each membrane strip and the rear-facing borders of air vapour barrier membrane 26 it contacts. In one embodiment, each membrane strip is applied with a seal between it and the air vapour barrier border against which the membrane strip is applied. In one embodiment, a sealant 42, such as a line of sealant, is positioned between the membrane strip and the air vapour barrier border to thereby create a seal between them, which is a portion of the building's overall air vapour barrier. An enlarged view is shown in
In one embodiment, membrane strips are coupled to the sheet material via a plurality of fasteners 46 secured along lengthwise edges 40′ of the vapour barrier membrane strips. The fasteners are driven through the membrane strip, through the air vapour barrier membrane and into the rear facing side of the sheet material. A sealant 50 is applied over the fasteners 46 to ensure that the air vapour barrier is not compromised. In one embodiment, the edges 40′ of the membrane strip are reinforced to better receive coupling by way of fasteners. For example, a durable strip 52, such as of metal can be positioned along lengthwise edges 40′ through which the fasteners can be secured. In one embodiment, the membrane wraps around both sides of the metal strip such that the metal strip is embedded in the membrane strip edge. With such an embodiment, air vapour barrier membrane strip 40 becomes clamped between the metal strip and the border of air vapour barrier membrane 26 on perimeter flange 18′.
Thus, the constructed wall 10 has a complete air vapour barrier comprising the air vapour barrier membrane 26 on the individual wall panels and the membrane strips 40 that span the gaps between the wall panels.
Because the membrane strips are installed on the back-facing side of the wall panels, the resulting air vapour barrier is readily visible and accessible and can be inspected and verified for quality compliance. In fact, visual inspection from the interior of the building can be undertaken. Being conducted from the interior of the building, the inspection is relatively safe and is possible even when finishes are complete on the exterior.
Membrane strips 40 are formed of a material that is flexible and substantially impermeable to vapour and air. For example, in one embodiment, membrane strips are formed of a resilient, elastomeric polymer such as rubber.
When the wall panel units are constructed into a wall, side edge flashing 30 and lower edge flashing 32 span the gaps G1, G2 between the front-facing planar surfaces of adjacent wall panels. Lower edge flashing 32 is positioned to extend down over an upper edge of a vertically adjacent wall panel below.
Flashings 30, 32 mitigate moisture ingress to the gaps G1, G2.
With reference to
This completes the air vapour barrier from wall unit to wall unit to create the building's overall air vapour barrier. To confirm that the air vapour barrier is properly installed, an inspection can be made from within the building by viewing the area where two panel units are installed side by side. Since the rear facing side border of each sheet of sheet material overhangs beyond its studs, it can be readily accessed and viewed. This being the location of the vapour barrier membrane strip, the proper placement and sealing of the strip can be verified.
The flashing 32 are lapped over the front facing side of adjacent wall panels, to span the gap G2 on the front facing. Although not illustrated, flashing 30 is also lapped over the front facing side of a side by side installation.
The above detailed description of example embodiments is not intended to be exhaustive or to limit this disclosure and claims to the precise forms disclosed above. While specific examples of, and examples for, embodiments are described above for illustrative purposes, various equivalent modifications are possible within the scope of the technology, as those skilled in the relevant art will recognize.
This application claims the benefit of U.S. Provisional Application No. 63/384,730, entitled “WALL PANEL AND METHOD FOR CONSTRUCTING A WALL” and filed on Nov. 22, 2022, which is expressly incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63384730 | Nov 2022 | US |
