WALL PANEL CLIP

Abstract

A kit for assembling prefabricated wall panels includes prefabricated wall panels and clips. Each side of the prefabricated wall panels is configured to form a side-lap joint and at least a tongue and groove joint upon assembly. Each clip includes a flange having a plurality of holes and a web that is connected to an edge of the flange and is at least 4 inches long. The clips may allow for greater panel spans and/or provide improved wind resistance. For assembling the prefabricated wall panels to a building structure, a clip is placed on a cheek surface of the side-lap joint of one of the prefabricated wall panels. Fasteners are threaded through the prefabricated wall panel to clamp an edge of the prefabricated wall panel between the clip and the building structure.

Description

BACKGROUND

This disclosure relates generally to methods and apparatus for assembling prefabricated wall panels, such as prefabricated wall panels constructed with a layer of insulation coupled to a pre-formed metal layer. More specifically, this disclosure relates to clips and methods for assembling prefabricated wall panels using such clips.

Metal walls have been in use in commercial and industrial construction. One type of metal walls system utilizes prefabricated wall panels. In many instances, the prefabricated wall panels are clamped to the building structure with a clamping mechanism that includes clips and screws.

For a given panel span, the strength and distribution of these clamping mechanisms affect the wind resistance of the wall. The distribution of these clamping mechanisms is constrained by the preexisting building structure to which the prefabricated wall panels are clamped and by the span of the prefabricated wall panels. In many cases, the strength of these clamping mechanisms is inadequate to provide sufficient wind resistance to the wall.

There is a continuing need in the art for methods and apparatus for assembling prefabricated wall panels that may allow for greater panel spans and/or provide improved wind resistance. Preferably, these clamping mechanisms are not exposed to the weather to avoid rain infiltration and/or corrosion. Also, these clamping mechanisms are preferably not visible from the exterior of the wall to preserve an aesthetically pleasing aspect to the metal wall.

SUMMARY

The disclosure describes a clip for assembling prefabricated wall panels.

The clip may comprise a flange. The flange may have a plurality of holes. For example, the plurality of holes comprises at least 3, and preferably 5 holes.

The clip may comprise a web. The web may be connected to a first edge of the flange. The web may be perpendicular to the flange. The web is located on a first side of the flange.

The clip may comprise a bevel. The bevel may be connected to a second edge of the flange that is opposite to the first edge. The bevel may be located on a second side of the flange that is opposite to the first side. The angle between the flange and the bevel may be obtuse.

In some preferred embodiments, the clip may be more than 4 inches long.

The disclosure also describes a kit for assembling prefabricated wall panels.

The kit may comprise a plurality of prefabricated wall panels. Each side of the plurality of the prefabricated wall panels may be configured to form a side-lap joint and at least a tongue and groove joint upon assembly.

The kit may comprise a plurality of clips, as described hereinabove. Upon assembly, when the flange is in place on a cheek surface of the side-lap joint, each of the plurality of clips may be configured so that the web is adjacent to an edge surface of the side-lap joint and the bevel does not interfere with a shoulder surface of the side-lap joint or a tongue of the tongue and groove.

The disclosure further describes a method for assembling prefabricated wall panels to a building structure.

The method may comprise the step of placing a clip as described hereinabove on a cheek surface of a side-lap joint of a prefabricated wall panel as described hereinabove. The web may extend inwardly toward the building structure upon assembly.

The method may comprise the step of threading a plurality of fasteners through the prefabricated wall panel to clamp an edge of the prefabricated wall panel between the clip and the building structure.

The method may comprise the step of vertically sliding another prefabricated wall panel to abut against the cheek surface of the side-lap joint.

The method may comprise the step of forming at least one tongue and groove joint between a side of the prefabricated wall panel and an adjacent side of the other prefabricated wall panel.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more detailed description of the embodiments of the disclosure, reference will now be made to the accompanying drawings, wherein:

FIG. 1 is a top sectional view of a portion of two adjacent panels forming a side-lap joint, one of the two adjacent panels is illustrated clamped to a building structure with a prior art clip;

FIG. 2A is a top view of the prior art clip shown in FIG. 1;

FIG. 2B is a side view of the prior art clip shown in FIG. 2B;

FIG. 3A is a top view of a clip in accordance with this disclosure;

FIG. 3B is a side view of the clip shown in FIG. 3A;

FIG. 4 is a side view of another clip in accordance with this disclosure;

FIG. 5 is a perspective view of a wall panel clamped to a building structure using the clip shown in FIG. 3A, 3B, or 4;

FIG. 6 is a perspective view of another clip in accordance with this disclosure; and

FIG. 7 is a perspective view of another clip in accordance with this disclosure.

DETAILED DESCRIPTION

Referring to FIG. 1, a portion of a metal wall 10 including at least two adjacent wall panels, such as first prefabricated wall panel 10A and second prefabricated wall panel 10B, is illustrated. The metal wall 10 separates an exterior side 12 from an interior side 18.

The prefabricated wall panels 10A, and 10 B include insulating foam 14, and facer plate 16. The insulating foam 14 is bonded to the facer plate 16 so that each of the prefabricated wall panels 10A and 10 B forms an integrated assembly. The insulating foam 14 may be foamed-in-place isocyanurate foam, polyisocyanurate foam, polyurethane foam, or other rigid thermal insulation. The facer plate 16 may be a metal sheet made of corrosion-resistant steel between 22-26 gauge (0.03 to 0.018 inches thick), or other metal material. Each prefabricated wall panels 10A and 10B may be between about 2.0 and about 8.0 inches thick, have a width between about 24 inches and about 45 inches, and a length between about 8 and about 75 feet. The prefabricated wall panels 10A, and 10 B may also have varying profiled portions 28, which may be formed by the facer plate 16, that strengthen and/or add visual interest to the outside surface of the metal wall 10.

The prefabricated wall panels 10A, and 10 B include interlocking features formed on opposite sides of each wall panel so that when assembled, the prefabricated wall panels 10A and 10B are interlocked by the interlocking features. The interlocking features form a splice joint or a scarf joint, and at least one tongue and groove joint. For example, the splice joint may be implemented as a side-lap joint. A side-lap joint generally includes an edge surface 36, a cheek surface 22, and a shoulder surface 34 formed on the prefabricated wall panel 10A. The edge surface 36, the cheek surface 22, and the shoulder surface 34 are configured to abut against the corresponding shoulder, cheek and edge surfaces formed on the prefabricated wall panel 10B. The shoulder surface 34 includes a tongue 24, which may be formed by the facer plate 16 on the exterior side 12 of the metal wall 10. The tongue 24 is sized to engage a groove 26 recessed within the edge surface of the prefabricated wall panel 10B, which may be formed by the facer plate 16 on the exterior side 12 of the metal wall 10. Preferably, the edge surface 36 of the prefabricated wall panel 10A also includes another tongue, which may be formed on the interior side 18 of the metal wall 10. The other tongue is sized to engage another groove recessed within the shoulder surface of the prefabricated wall panel 10B, which may be formed on the interior side 18 of the metal wall 10.

Each wall panel may be coupled to a building structure 50 by a plurality of clips 30 and screws 44 as needed for the particular design. For example, the prefabricated wall panels 10A and 10B are installed by placing the prefabricated wall panel 10A vertically onto the building structure 50. A clip 30, including a base flange 32 (shown in FIG. 2), is used to clamp the prefabricated wall panels 10A to the building structure 50. The clip 30 is placed on the prefabricated wall panel 10A so that the base flange 32 rests on the cheek surface 22 The base flange 32 includes a plurality of holes 40 (shown in FIG. 2) to enable the clip 30 to be fastened to the building structure 50 with screws 44. Accordingly, the screws 44 are inserted through the holes 40 on the clip 30 and clamp the prefabricated wall panel 10A to the building structure 50.

Once the prefabricated wall panel 10A is coupled to the building structure 50, the prefabricated wall panel 10B is slid horizontally into place so that the groove 26 engages the tongue 24. In certain embodiments, non-skinning butyl caulk 46, or other sealant, may be applied to the tongue 24 and/or the groove 26 before engagement thereof. The prefabricated wall panel 10B covers the clip 30 and/or the screws 44.

Referring to FIGS. 2A and 2B, the clip 30 includes the base flange 32 having on one edge a strip of metal that is bent to form a rim 20. As used herein, a rim is a feature that facilitates the alignment of the base flange 32 with the edge 36, but does not significantly increase the overall stiffness or strength of the clip 30. For example, a rim may increase the bending stiffness or strength of the clip 30 by less than 10 to 50%. The length of the clip 30 may be approximately 4.0 inches; the width of the clip 30 may be approximately 1.4 inches; the height of the rim 20 may be approximately equal to 0.2 inch; and the angle between the base flange 32 and the rim 20 may be obtuse (e.g., approximately 100 degrees). The clip 30 includes five holes 40 having a diameter of approximately 0.3 inch. Note that, in use, not all the holes may receive a screw.

A clip 54 that allows for greater panel spans and/or provides improved wind resistance is illustrated in FIGS. 3A and 3B. The clip 54 may be made of corrosion-resistant steel 14-gauge (approximately 0.07 inch thick), having a yield strength of at least 50 ksi. The clip 54 includes a flange 38, a web 42, a bevel 56, and a plurality of pre-punched holes 48. As used herein, a web also facilitates the alignment of the base flange 32 with the edge 36. In contrast with a rim, a web significantly increases the overall stiffness or strength of the clip 30. For example, a rim may increase the bending stiffness or strength of the clip 30 by more than 50 to 100%. The web 42 and the bevel 56 are connected to the flange 38 at opposite edges of the flange 38. The flange 38 is preferably flat. The web 42 and the bevel 56 are not located in the same plane as the flange 38; preferably, the web 42 and the bevel 56 are located on opposite sides of the flange 38. The purpose of the web 42 is to add bending strength to and stiffen the clip 54 and/or the flange 38. The purpose of the bevel 56 is similar to the purpose of the web 42; it is to add bending strength and further stiffen the clip 54 and/or the flange 38. The length of the clip 54 is approximately at least 4.0 inches long, preferably approximately 8.0 inches, so it may be approximately the double of the length of the clip 30; the width of the clip 54 may be approximately 1.4 inches; the height of the web 42 may be approximately equal to ¾ inch; the angle between the flange 38 and the web 42 may be perpendicular (i.e., approximately 90 degrees); the length of the bevel 56 may be approximately 0.7 inch; and the angle between the flange 38 and the bevel 56 may be obtuse (e.g., approximately 135 degrees). The web 42 extends on only one side of the flange 38 (e.g., the inner side), and the flange 38 extends on only one side of the web 42 (e.g., the left side). The clip 54 includes a minimum of three pre-punched holes 48 having a diameter of approximately 0.3 inch.

Another clip 52 that allows for greater panel spans and/or provides improved wind resistance is illustrated in FIG. 4. The clip 52 may be made of corrosion-resistant steel 12-gauge (approximately 0.1 inch thick), having a yield strength of at least 50 ksi. Increasing the thickness of the clip may stiffen and/or strengthen the clip retaining the panel. The shape of the clip 52 differs from the shape of the clip 54 primarily by its length, which is approximately 12 inches. Increasing the length of the clip may also allow a better distribution of the loads retaining the panel.

The clips 52 and/or 54 may be used similarly as the clip 30 shown in FIGS. 1, 2A, and 2B.

Referring to FIG. 5, the prefabricated wall panel 10A is clamped to the building structure 50 using the clip 54 shown in FIGS. 3A, 3B, or the clip 52 shown in FIG. 4 and screws 44 (or other fasteners). When the flange of the clip 52 and/or 54 is in place on the cheek surface 22 formed on the prefabricated wall panel 10A, the web of the clip 52 and/or 54 extends inwardly toward the building structure 50 and is adjacent to the edge surface 36 of the prefabricated wall panel 10A. The bevel of the clip 52 and/or 54 does not interfere with the shoulder surface 34 and/or the tongue 24 of the prefabricated wall panel 10A.

Another clip 58 that allows for greater panel spans and/or provides improved wind resistance is illustrated in FIG. 6. The clip 58 may be made of corrosion-resistant steel 14-gauge (approximately 0.07 inch thick), having a yield strength of at least 50 ksi. The shape of the clip 58 differs from the shape of the clip 54 shown in FIGS. 3A and 3B primarily by the number of pre-punched holes. The spacing between the pre-punched holes may be the same as in FIGS. 3A and 3B. Increasing the number of holes (e.g., to 5 holes) may provide more flexibility to the installer regarding fastener placement. While only 3 screws may often be required, it may be easier to install three screws on a variety of substrates if they are spread out. For example, the 3 fasteners may be installed in the first, third, and fifth holes, that is, every other hole. The 3 fasteners may still be installed in the second, third, and fourth holes, that is, in consecutive holes. Also, increasing the number of holes (e.g., to 5 holes) may allow a better distribution of the loads applied by the screws.

Another clip 60 that allows for greater panel spans and/or provides improved wind resistance is illustrated in FIG. 7. The clip 60 may be made of corrosion-resistant steel 12-gauge (approximately 0.10 inch thick), having a yield strength of at least 50 ksi. The shape of the clip 60 differs from the shape of the clip 54 shown in FIGS. 3A and 3B primarily by the number of pre-punched holes and by its length, which is approximately 12 inches.

The clips 58 and/or 60 may also be used as shown in FIG. 5.

In other embodiments, the clips may be 4 or 6 inches long.

Specific embodiments are shown by way of example in the drawings and description. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the disclosure to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.

Claims

1. A clip for assembling prefabricated wall panels, comprising: a flange having a plurality of holes;a web that is perpendicular to the flange, wherein the web is connected to a first edge of the flange.

2. The clip of claim 1, further comprising a bevel, wherein the bevel is connected to a second edge of the flange, the second edge being opposite to the first edge.

3. The clip of claim 2, wherein the web is located on a first side of the flange, wherein the bevel is located on a second side of the flange, the second side being opposite to the first side.

4. The clip of claim 2, wherein the angle between the flange and the bevel is obtuse.

5. The clip of claim 1, wherein the plurality of holes comprises at least 3 holes.

6. A kit for assembling prefabricated wall panels, comprising: a plurality of clips, each of the plurality of clips including: a flange having a plurality of holes;a web that is perpendicular to the flange, wherein the web is connected to a first edge of the flange; anda plurality of prefabricated wall panels,wherein each side of the plurality of the prefabricated wall panels is configured to form a side-lap joint and at least a tongue and groove joint upon assembly.

7. The kit of claim 6, wherein each of the plurality of clips is configured so that the web is adjacent to an edge surface of the side-lap joint when the flange is in place on a cheek surface of the side-lap joint.

8. The kit of claim 7, wherein each of the plurality of clips further comprises a bevel, wherein the bevel is connected to a second edge of the flange, the second edge being opposite to the first edge.

9. The kit of claim 8, wherein each of the plurality of clips is configured so that the bevel does not interfere with a shoulder surface of the side-lap joint or a tongue of the tongue and groove upon assembly.

10. The kit of claim 9, wherein the web is located on a first side of the flange, wherein the bevel is located on a second side of the flange, the second side being opposite to the first side.

11. The kit of claim 9, wherein the angle between the flange and the bevel is obtuse.

12. The kit of claim 6, wherein the plurality of holes comprises at least 3 holes.

13. A method for assembling prefabricated wall panels to a building structure, comprising: placing a clip on a cheek surface of a side-lap joint of a prefabricated wall panel, wherein the clip includes: a flange having a plurality of holes;a web that is perpendicular to the flange, wherein the web is connected to a first edge of the flange;threading a plurality of fasteners through the prefabricated wall panel to clamp an edge of the prefabricated wall panel between the clip and the building structure; andvertically sliding another prefabricated wall panel to abut against the cheek surface of the side-lap joint; andforming at least one tongue and groove joint between a side of the prefabricated wall panel and an adjacent side of the other prefabricated wall panel.

14. The method of claim 13, wherein each of the plurality of clips is configured so that the web is adjacent to an edge surface of the side-lap joint when the flange is in place on a cheek surface of the side-lap joint.

15. The method of claim 14, wherein each of the plurality of clips further comprises a bevel, wherein the bevel is connected to a second edge of the flange, the second edge being opposite to the first edge.

16. The method of claim 15, wherein the bevel does not interfere with a shoulder surface of the side-lap joint or a tongue of the tongue and groove upon assembly.

17. The method of claim 16, wherein the web is located on a first side of the flange, wherein the bevel is located on a second side of the flange, the second side being opposite to the first side, wherein the web extends inwardly toward the building structure upon assembly.

18. The method of claim 17, wherein the angle between the flange and the bevel is obtuse.

19. The method of claim 16, wherein the plurality of holes comprises at least 3 holes.