TREA

WALL PANEL MOUNT SYSTEM INCLUDING FRAMES SNAP-FIT CONNECTABLE TO A WALL VIA A CLIP

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Information

  • Patent Application
  • 20250146293
  • Publication Number
    20250146293
  • Date Filed
    March 27, 2024
    a year ago
  • Date Published
    May 08, 2025
    a month ago
  • Inventors
    • MORLOCK; Nathan
  • Original Assignees
    • MORLOCK HOLDINGS LTD.
Information
Abstract
There is provided a wall panel mount system including first and second frames connectable to first and second wall panels, respectively. The wall panel mount system includes a clip connectable to a wall or wall substrate. The clip snap-fit connects to the first frame and slidably connects to the second frame. The clip includes a clip snap interface or first male portion which snap-fit connects to the first frame and a clip slide function interface or second male portion which slidably couples to and/or extends within a female portion of the second frame according to one aspect. The clip is configured to snap-fit connect to the first frame via a folded portion thereof according to another aspect. Each frame includes an inner channel with one or more angled surfaces shaped to facilitate insertion of the clip therein according to a further aspect.
Description
BACKGROUND OF THE INVENTION
Field of the Invention

There is provided a mount system. In particular, there is provided a wall panel mount system including a plurality of frames snap-fit connectable to a wall via a clip, and a wall panel assembly comprising the same.


Description of the Related Art

United States Patent Application Publication No. 2009/0241444 A1 to Griffiths discloses a wall panel system includes a mounting bracket with a longitudinally extending first channel and a longitudinally extending second channel. The system includes a wall panel with a perpendicular flange around its periphery. The wall panel is attached to the mounting bracket by a clip attached to the wall panel adjacent the flange, the clip having an engaging element with a first portion and a second portion. The clip is secured to the mounting bracket by either the first portion of the engaging element mating with the second channel, or the second portion mating with the first channel. The first portion of the engaging element and the second channel each include a protrusion, the interaction of the protrusions causing the first portion to snap into the second channel.


U.S. Pat. No. 7,716,891 to Radford discloses panels attached to extrusions by fasteners. Clips are attached to a structure by fasteners. The extrusions and the clips engage in a manner which allows the panels to move in any direction, as needed, without the panel detaching from the structure and falling. The extrusions also provide for the use of optional reveal strips. An extrusion has a restraining area, a reveal strip stop area, and a T-slot. A clip has a T-channel, a tensioning stop arm, and a secondary reinforcing arm. The panels can be installed in rows, in columns, or diagonally, as desired.


U.S. Pat. No. 8,316,599 to Griffiths discloses a wall panel system which includes at least one wall panel. Each edge of the panel has a flange. At least one flange, and preferably two opposing flanges, have at least one slot therein. Each slot is mated with a clip having two extensions laterally spaced from one another, one of said extensions having a latch member protruding in a direction toward the other of said extensions, such that the clip is secured to the flange by virtue of the latch member mating with the slot. The clip may then be attached to a building surface or intermediary mounting apparatus by a fastener to secure the wall panel thereto.


U.S. Pat. No. 9,850,666 to Libreiro discloses a panel system for covering a building wall. The panel system includes at least one panel assembly. Each panel assembly includes a panel having a front panel wall, a side panel wall, and a back mounting flange overhanging the front panel wall. Each panel also includes at least one perimeter extrusion. Each perimeter extrusion includes a panel engaging portion having a panel slot shaped to receive the back mounting flange of the panel, and a connector engaging portion having a connector slot. The panel system also includes at least one connector extrusion for mounting the panel assembly to the building wall. Each connector extrusion includes a connector base mountable to the building wall, and at least one connector flange shaped to fit in the connector slot of the perimeter extrusion.


The above-described prior art may suffer a number of disadvantages.


BRIEF SUMMARY OF INVENTION

There is provided, and it is an object to provide, an improved wall panel mount system, including a frame and clip thereof, as well as a wall panel assembly comprising the same, disclosed herein.


There is accordingly provided a wall panel mount system according to one aspect. The wall panel mount system includes first and second frames connectable to first and second wall panels, respectively. The wall panel mount system includes a clip connectable to a wall or wall substrate. The clip includes a clip snap interface or first male portion which snap-fit connects to the first frame. The clip includes a clip slide function interface or second male portion which slidably couples to and/or extends within a female portion of the second frame.


There is also provided a wall panel mount system according to another aspect. The wall panel mount system includes a pair of frames connectable to a pair of wall panels. The wall panel mount system includes a clip connectable to a wall or wall substrate. The clip is configured to snap-fit connect to a first said frame via a folded portion thereof. The clip is configured to slidably connecting to a second said frame.


There is further provided a wall panel mount system according to an additional aspect. The wall panel mount system includes a pair of frames connectable to a pair of wall panels. The wall panel mount system includes a clip connectable to a wall or wall substrate. The clip snap-fit connects to a first said frame and slidably connects to a second said frame. Each frame includes an inner channel with one or more angled surfaces shaped to facilitate insertion of the clip therein.


There is also provided a wall panel mount system according to an additional aspect. The wall panel mount system includes at least a pair of frames connectable to at least a pair of wall panels. The pair of frames are shaped to snap-fit together via a clip. There may be other frames and/or other wall panels in other embodiments. A first said frame is shaped to snap fit with one side of a clip which couples to a wall or wall substrate. A second said frame may interface with another folded side (180 degree fold) of the clip in a non-snap connection interface.


There is additionally provided a clip for a wall panel mount system according to one aspect. The clip is shaped to mount a pair of wall panels to a wall or wall substrate by snap-fit connecting together a pair of frames each connected to a respective said wall panel. According to one example, a full clip is snap fit to a first panel via a first frame, folded onto itself by 180 degrees and mounted to the wall with fastener. The clip in one non-limiting embodiment includes a slide connection (non snap) to a second panel using a male part of the folded clip which extends into the female channel of a second frame.


There is further provided a wall panel assembly according to one aspect. The wall panel assembly includes a plurality of longitudinally-extending frames. The wall panel assembly includes a first wall panel configured to couple to a wall or wall substrate via a first said frame and at least a first fastener coupling together the first said frame and a side or side portion of the first wall panel. The wall panel assembly includes a second wall panel configured to couple to the wall or wall substrate via a second said frame and a second fastener coupling together the second said frame and a rear or rear portion of the second wall panel. In one non-limiting embodiment, each wall panel may be configured to couple to the wall or wall substrate via its corresponding frame and at least a snap fit clip and a fastener which extends through the clip and into the wall or wall substrate.


There is also provided a wall panel assembly according to an additional aspect. The wall panel assembly includes a plurality of longitudinally-extending frames. The wall panel assembly includes a plurality of first wall panels each configured to couple to a wall or wall substrate via a respective first said frame and at least a first said fastener coupling together the first said frame and a side or side portion of the first wall panel thereof. The wall panel assembly includes a plurality of second wall panels each configured to couple to the wall or wall substrate via a respective second said frame and at least a second said fastener coupling together the frame and a rear or rear portion of the second wall panel thereof. In one non-limiting embodiment, each wall panel may be configured to couple to the wall or wall substrate via its corresponding frame and at least a snap fit clip and a fastener which extends through the clip and into the wall or wall substrate.


It is emphasized that the invention relates to all combinations of the above features, even if these are recited in different claims.


Further aspects and example embodiments are illustrated in the accompanying drawings and/or described in the following description.





BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings illustrate non-limiting example embodiments of the invention.



FIG. 1 is a front, top, left side perspective view of a wall panel mount system and wall panel assembly according to one aspect, with the wall panel assembly including a plurality of fastener-hidden wall panels which operatively couple to a wall or wall substrate via wall panel fasteners which are hidden when viewed from the exterior thereof;



FIG. 2 is a rear, top, right side perspective view thereof;



FIG. 3 is a rear, top, right side exploded view thereof;



FIG. 4 is a sectional view taken along either of lines 4-4 of the wall panel mount system and wall panel assembly of FIG. 1;



FIG. 5 is a sectional view taken along either of lines 5-5 of the wall panel mount system and wall panel assembly of FIG. 1;



FIG. 6 is a front, top, left side perspective view of the wall panel mount system of FIG. 1, together with a plurality of wall panels of the wall panel assembly of FIG. 1 according to another aspect, the wall panels being fastener-exposed wall panels which operatively couple to the wall or wall substrate via wall panel fasteners which are exposed at least in part when viewed from the exterior thereof;



FIG. 7 is a rear, top, right side perspective view thereof;



FIG. 8 is a rear, top, right side exploded view thereof;



FIG. 9 is a sectional view taken along either of lines 9-9 of the wall panel mount system and wall panel assembly of FIG. 6;



FIG. 10 is a sectional view taken along either of lines 10-10 of the wall panel mount system and wall panel assembly of FIG. 6;



FIG. 11 is a rear, inner side, end perspective view of a frame of the wall panel mount system of FIGS. 1 and 6;



FIG. 11A is an enlarged rear, inner side, end perspective view thereof;



FIG. 12 is a rear, end, right side perspective view of a full clip for the wall panel mount system of FIGS. 1 and 6, with the full clip being shown in an unfolded/unassembled mode;



FIG. 13 is a rear, end, right side perspective view thereof, with the full clip being shown in a fold/assembled mode ready for use;



FIG. 14 is a rear, end, right side perspective view of a half clip for the wall panel mount system of FIGS. 1 and 6;



FIG. 15 is a sectional, rear, inner side perspective view of one of the wall panels of FIG. 1 together with one of the frames of FIG. 11 coupled thereto, with the wall panel and frame being shown in fragment;



FIG. 16 is a sectional, front, outer side perspective view thereof, with the wall panel and frame being shown in fragment;



FIG. 17 is a front, top, left side perspective view of the wall panel mount system of FIG. 1, together with a plurality of wall panels of the wall panel assembly of FIG. 1 according to a further aspect, each wall panel comprising a combination fastener-hidden and fastener-exposed wall panel which operatively couples to the wall or wall substrate via wall panel fasteners which are hidden along the bottom and sides thereof and which are exposed along the top thereof;



FIG. 18 is a sectional view taken along either of lines 17-17 of the wall panel mount system and wall panel assembly of FIG. 17;



FIG. 19 is a side, top, front perspective view of the fastener-exposed wall panel of FIG. 6 together with a punching apparatus for forming a dimpled or recessed portion about apertures thereof, with the wall panel being shown in fragment;



FIG. 20 is a side, top perspective view thereof;



FIG. 21 is an enlarged perspective view of a protrusion of the punching apparatus of FIG. 19 shown in the process of pressing into one said aperture of the wall panel of FIG. 19 so as to form a dimpled or recessed portion thereabout, with the wall panel and punching apparatus being shown in fragment;



FIG. 22 is a side perspective view of the wall panel of FIG. 19, with a fastener extending through the dimpled or recessed portion of the wall panel so formed, and with the wall panel being shown in fragment; and



FIG. 23 is a sectional view taken along lines 23-23 of the wall panel, dimpled or recessed portion thereof and fastener of FIG. 22.





DESCRIPTION OF THE PREFERRED EMBODIMENTS

Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive sense.


Referring to the drawings and first to FIG. 1, there is shown a wall panel assembly 30. The wall panel assembly includes a plurality of wall panels, in this example including a first set of wall panels 32, in this non-limiting instance four wall panels 32A, 32B, 32C and 32D. The first set of wall panels are configured to couple to a wall or wall substrate 34 seen in FIG. 4. The wall substrate is part of a structure, in this non-limiting example a building 35. Wall panels 32A and 32B are configured to operatively couple to wall substrate 34 in a manner which inhibits wall panel fasteners 36, 36A and 36B or other coupling members thereof, from being seen when viewing the wall panels from exterior 38 thereof seen in FIG. 1. The first set of wall panels 32A, 32B, 32C and 32D may be referred to as a fastener-hidden wall panels or rear-fastened wall panels. The first set of wall panels may be positioned in a more visible/prominent and/or lower portion of wall substrate 34 of building 35 seen in FIG. 4, though this is not strictly required. For example, in other embodiments, fastener-hidden wall panels 32A and 32B may substantially cover the whole of the wall substrate.


As seen in FIG. 6, the plurality of wall panels of wall panel assembly 30 in this non-limiting embodiment includes a second set of wall panels 32, in this non-limiting instance four wall panels 32E, 32F, 32G and 32H. The second set of wall panels are configured to operatively couple to wall substrate 34 seen in FIG. 9 via wall panel fasteners 36, 36E and 36F which are exposed at least in part when the wall panels are viewed from exterior 38 thereof seen in FIG. 1. The second set of wall panels 32E, 32F, 32G and 32H may be referred to as a fastener-exposed wall panels or side-fastened wall panels. The second set of wall panels may be positioned in a less visible/prominent and/or an elevated portion of wall substrate 34 of building 35 seen in FIG. 9, though this is not strictly required. In other embodiments, fastener-exposed wall panels 32E and 32F may substantially cover the whole of the wall substrate, with wall panel assembly 30 not including fastener-hidden wall panels 32A, 32B, 32C and 32D seen in FIG. 1.


As seen in FIG. 17, the plurality of wall panels of wall panel assembly 30 in this non-limiting embodiment includes a third set of wall panels 32, in this non-limiting instance four wall panels 32I, 32J, 32K, and 32L. The third set of wall panels are configured to operatively couple to wall substrate 34 seen in FIG. 18 via one or more wall panel fasteners 36L which are exposed one or more fastener-exposed portions of sides thereof, in this non-limiting example top sides 44B thereof, when the wall panels are viewed from exterior 38 thereof. Third set of wall panels 32I, 32J, 32K and 32L are configured to operatively couple to wall substrate 34 seen in FIG. 18 via one or more wall panel fasteners 36I along one or more fastener-hidden portions or sides thereof, in this non-limiting example side portions 44A and 44B and bottom side 44D thereof, where the fasteners couple in a manner which inhibits the fasteners or other coupling members thereof, from being seen when viewing the wall panels from exterior 38 thereof. Each of the third set of wall panels 32I, 32J, 32K and 32L seen in FIG. 17 may thus be referred to as a combination fastener-exposed and fastener-hidden wall panel. The third set of wall panels may be positioned in a less visible/prominent and/or an elevated portion of wall substrate 34 of building 35 or at least in positions where top sides 44B of the wall panels are not readily seen or viewable, though this is not strictly required. In other embodiments, fastener-exposed wall panels 32E and 32F may substantially cover the whole of the wall substrate, with wall panel assembly 30 not including fastener-hidden wall panels 32A, 32B, 32C and 32D seen in FIG. 1. Any combination of wall panels from the first, second or third sets thereof seen in FIGS. 1, 6 and 17 may be arranged/used/provided in other embodiments.


Referring back to FIG. 6, each wall panel 32 is made of an aluminum composite material in this non-limiting embodiment. However, this is not strictly required and the wall panels may be made of other materials in other embodiments. Each wall panel 32 is made into a pan-type shape in this non-limiting example. Wall panel 32 is made of a first metal 32.1 seen in FIG. 23 in this non-limiting example with one or more outer layers or non-metal coating 32.1′ and 32.1″ thereon. In this non-limiting embodiment the first metal may comprise aluminium in the form of aluminium plate, which may be ⅛ inches thick; however, here too this is not strictly required. Wall panels per se, including their various parts and functionings, are known per se and example materials/subcomponents of wall panels 32 will accordingly not be described in further detail.


As seen in FIG. 1, the wall panels in this non-limiting embodiment are arranged in rows R1, R2, RN etc. of wall panels 32A and 32B, 32C and 32D etc. extending parallel to a first longitudinal or in this non-limiting example horizontal axis 31 of wall panel assembly 30. The wall panels in this non-limiting embodiment are also arranged in columns C1, C2, CN etc. of wall panels 32A and 32C, 32B and 32D etc. extending parallel to a second longitudinal or in this non-limiting example vertical axis 33 of the wall panel assembly. However, this is not strictly required and the wall panels may be arranged in other manners and/or in angled and/or non-horizontal/vertical arrangements in other embodiments.


Also, this number order is not intended to indicate the order in which the wall panels must be installed. For example, in one non-limiting embodiment, an installer may: i) arrange/install wall panels in an order of bottom left (panel 32C), bottom right (panel 32D), and continue along bottom to complete row R2 while checking and maintaining the level of the same; and ii) next arrange/install the wall panels in an order of top left (panel 32A), top right (panel 32B) along the next row R1 thereabove etc. In this manner the wall panels may thus be installed so as to couple to the wall or wall substrate of the building along sequential rows in a bottom up direction in this non-limiting example.


As seen in FIG. 4, each wall panel 32A has a front 40 that is outwardly facing towards exterior 38 and a rear 42 spaced-apart from the front thereof. Each wall panel includes a central portion 43 extending along the front thereof. As seen in FIG. 1, the central portion of wall panel 32 is polygonal in shape, in this non-limiting embodiment being square-shaped with non-limiting dimensions of 48 inches by 48 inches for example; however, this is not strictly required. In other non-limiting embodiments the wall panels may be comprise other polygonal shapes in other embodiments (e.g. triangular, rectangular, quadrilateral, pentagonal, hexagonal etc..


Still referring to FIG. 1, each wall panel 32 includes a plurality of sides 44 extending between front 40 and rear 42 thereof: in this non-limiting example each wall panel has a first or right side 44A, a second or top side 44B (or top), a third or left side 44C spaced-apart from the right side thereof, and a bottom side 44D (or bottom) spaced-apart from the top side thereof. The top and bottom sides of the wall panel may extend between the left and right sides of the wall panel in this example. Each wall panel 32A includes at least one and in this example a plurality of side portions 46, 46A, 46B, 46C, and 46D. For each wall panel the side portions thereof extend along respective sides 44A, 44B, 44C and 44D thereof. For each wall panel 32 side portions 46A, 46B, 46C and 46D thereof couple to and extend about or around central portion 43 thereof. Each side portion is rectangular in shape in this non-limiting example; however, this is not strictly required. As seen in FIG. 4, for each wall panel 32A side portions 46C thereof extends laterally outwards from and in this non-limiting example perpendicular to central portion 43 thereof. For each wall panel the side portions thereof are integrally connected to the central portion thereof so as to form a unitary whole in this non-limiting example. To achieve this shape, in one non-limiting embodiment there may be a router machined groove at the back side of the panel sheet (about 130 degree tool cut) for easy of forming the 90 degree bends.


As seen in FIG. 9, each wall panel 32 has an outer side, front face or exterior surface 45 aligned with front 40 thereof and facing exterior 38. Each wall panel has an inner side or interior surface 47 opposite the exterior surface thereof. The interior surface of wall panel 32 faces wall substrate 34 in this non-limiting example. For each wall panel 32, exterior surface 45 and interior surface 47 thereof are square in shape in this non-limiting embodiment; however, this is not strictly required. In other non-limiting embodiments, the exterior and interior surfaces may comprise other polygonal shapes, such as being triangular, rectangular, quadrilateral, pentagonal, hexagonal etc. Inner surface 47 of wall panel 32 is configured to face the wall or wall substrate 34.


Still referring to FIG. 9, each wall panel 32 has a periphery 50. For each of the fastener-exposed wall panels 32E and 32F, the periphery thereof comprises side portions 46C and peripheral regions of central portion 43 thereof adjacent thereto. For each fastener-exposed wall panel seen in FIG. 9, periphery 50 thereof is thus L-shaped in lateral profile adjacent in this non-limiting example. Each fastener-exposed wall panel 32E in one non-limiting embodiment may be said to comprise a single ninety-degree bend between central portion 43 and each side portion 46C thereof, with the side portion(s) thereof or return, being three quarters of an inch in lateral section in one non-limiting example.


Referring to FIG. 3, each fastener-hidden wall panel 32A in this non-limiting embodiment includes at least one and in this example a plurality of rear portions 48, 48A, 48B, 48C and 48D coupled to and extending inwards from respective side portions thereof 46A, 46B, 46C and 46D thereof. This is best seen in FIG. 4 for wall panel 32A with rear portion 48C thereof coupling to and extending inwards from side portion 46C thereof. For each fastener-hidden wall panel the rear portions thereof are rectangular in this non-limiting example; however this is not strictly required. Rear portions 48A and 48C of wall panels 32A and 32B extend along rear 42 of the wall panel. The rear portions of the fastener-hidden wall panels extend parallel to central portions 43 of the wall panels in this non-limiting example; however, this is not strictly required. For each fastener-hidden wall panel 32A, rear portions 48C thereof are integrally connected to respective side portions 46C thereof so as to form a unitary whole; however, here too this is not strictly required.


Each fastener-hidden wall panel has a periphery 51 comprising side portions 46C thereof, peripheral regions of central portion 43 thereof adjacent thereto and rear portions 48C thereof in this example. The periphery of each fastener-hidden wall panel is C-shaped in lateral section in this non-limiting embodiment, though this is not strictly required. A longitudinally-extending channel or recess 52 is formed by central portion 43, rear portions 48C and side portions 46C of wall panel 32A in this non-limiting example. The recess is rectangular in lateral profile and extends about periphery 51 of the fastener-hidden wall panel in this non-limiting embodiment. Fastener-hidden wall panel 32A in one non-limiting embodiment may be said to comprise a double return with a ninety-degree bend between central portion 43 and side portion 46C thereof, with the side portion(s) thereof or return, being three-quarters of an inch in lateral section, with additional ninety-degree bend between the side portion(s) and rear portion 48C thereof, and with the rear portion or additional return being one inch in lateral section to form a U-shaped perimeter in one non-limiting embodiment.


As seen in FIG. 16, each wall panel 32 has at least one and in this example a plurality of longitudinally-spaced apertures, in this example weep holes 53, 53A, 53B and 53C. The weep holes extend about respective axes 53A′, 53B′ and 53C′ which each extend substantially parallel with each other in this non-limiting embodiment. The axes of weep holes 53, 53A, 53B and 53C extend substantially parallel to exterior surface 45 of wall panel 32 in this non-limiting example. For each wall panel the weep holes thereof extend through an exterior or periphery 50 thereof. For each wall panel 32 weep holes 53A, 53B and 53C thereof are shaped to extend along and through side portion 46 thereof, in this example a bottom side portion thereof 46D. The weep holes are incorporated for drainage at the bottom of each wall panel. Each weep hole is obround in side profile in this non-limiting example. Each weep hole 53 is slot shaped in this non-limiting embodiment. For each wall panel 32 one weep hole 53B thereof may be centrally positioned along side 44 thereof in one non-limiting embodiment. As seen in FIG. 1, weep holes 53, 53A, 53B, and 53C may be configured to extend through only one or a bottom, lower and/or downward-facing side portion 46D of wall panel 32A. In one non-limiting embodiment for each wall panel 32A: a first weep hole 53A thereof extending through side portion 46D thereof is near or adjacent a first or right side portion 46A thereof; and a second weep hole 53C thereof extending through side portion 46D thereof is near or adjacent a second or left side portion 46A thereof. In a further non-limiting embodiment, for each wall panel, at least one third weep hole 53B thereof extends through side portion 46D thereof between weep holes 53A and 53C and between side portions 46A and 46C thereof.


Referring now to FIG. 3, wall panel assembly 30 includes a wall panel mount system 54. Alternatively, the wall panel mount system may be said to be separate from the wall panel assembly and rather, for the wall panel assembly. The latter may be but need not be a third-party product.


Wall panel mount system 54 includes a plurality of frames 56. Each frame may be made of or comprise extruded material such as aluminum in this non-limiting embodiment; however, this is not strictly required. Frames 56 may be referred to as perimeter frame with vertical stiffeners for support in this non-limiting example. Each wall panel 32 includes one or more frames associated therewith. In this example and as seen in FIG. 3, frames 56A, 56B, 56C and 56D are shaped to couple to and extend along sides 44A, 44B, 44C, and 44D of the wall panels. For each wall panel 32A each side portion 46A, 46B, 46C and 46D thereof is shaped to couple to a respective frame in this non-limiting embodiment. As seen in FIG. 2, the frames may be mitered, with adjacent frames 56A and 56B being shaped to abut each other in this non-limiting embodiment via a miter joint 59. In this non-limiting example frames 56A, 56B, 56C and 56D are mitered at forty-five degrees at corners 61A, 61B, 61C and 61D thereof. The frames in this non-limiting example are tightly and/or snugly fit together and tack welded to strengthen the corner connection and to ensure wall panel 32A maintains its square or promote corners comprised of frames coupling together adjacent thereto at substantially 90 degrees to each other. Tightly mitered corners may function to improve rainscreen performance of wall panel assembly 30 and/or wall panel mount system 54 by inhibiting wind driven rain from reaching and/or being retained in corners 61A, 61B, 61C and 61D. As seen in FIG. 4, frames 56, 56A and 56B are configured to be installed about the inside of the pan-shape of their respective wall panels 32A and 32B for structural support.


Each frame 56 is configured to couple to wall substrate 34 either rear-fastened/fastener-hidden wall panels 32A/32B/32C/32D seen in FIG. 1, side-fastened/fastener-exposed wall panels 32E/32F/32G/32H seen in FIG. 6 or hybrid or a combination fastener-hidden and fastener-exposed wall panels 32I/32J/32K/32L seen in FIG. 17. The frames may thus be said to be universal, with each frame being configured to selectively operatively connect either type of wall panel to wall substrate 34 of building 35. The following is a non-limiting embodiment which achieves this functionality.


As seen in FIG. 11A, each frame 56 has an inner end 58 shaped to be near or adjacent wall substrate 34 and an outer end 60 spaced-apart laterally outwards from the inner end thereof. The inner and outer ends of the frame align along or parallel to a first lateral plane/axis, in this non-limiting example a first horizontal plane/axis 62 seen in FIG. 4. However, the latter is not strictly required as the wall panels (and frames thereof) may be installed at an angle relative to the vertical and/or horizontal planes. Inner end 58 of frame 56 is shaped to face wall substrate 34 of building 35 in this non-limiting example. The inner end of the frame is shaped to be near or adjacent the wall substrate in this non-limiting embodiment. Inner end 58 of frame 56 is shaped to extend substantially parallel to wall substrate 34 in this example; however, this is not strictly required.


Outer end 60 of frame 56 is positioned to be adjacent corresponding wall panel 32A of the frame in this non-limiting example. The outer end of the frame is shaped to extend parallel to and abut interior surface 47 of the wall panel in this non-limiting embodiment. Outer end 60 of frame 56 is shaped to extend parallel to central portion 43 of corresponding wall panel 32A.


Referring back to FIG. 11A, each frame 56 has an inner side 64 and an outer side 66 spaced-apart from the inner side thereof. As seen in FIG. 4, the inner and outer sides of frame 56 align along or substantially parallel to a second lateral plane/axis, in this non-limiting example a second horizontal plane/axis 68. Here too the latter is not strictly required as the wall panels (and frames thereof) may be installed at an angle relative to the vertical and/or horizontal planes. Plane/axis 68 is angled and in this non-limiting embodiment perpendicular to plane/axis 62. Inner side 64 of frame 56 faces interior surface 47 and/or rear 42 of wall panel 32A at least in part in this non-limiting example. Outer sides 66 of adjacent or paired frames 56A and 56B are configured to face each other in this non-limiting embodiment.


Referring back to FIG. 11, each frame 56 includes a first lateral end portion 70 and a second lateral end portion 72 spaced-apart from the first lateral end portion thereof. The lateral end portions of the frame may be mitered, though this is not shown in FIG. 11 for ease of illustration. Each frame 56 has a longitudinal axis 74 extending between the lateral end portions 70 and 72 thereof. The longitudinal axis of frame 56 in this non-limiting example extends perpendicular/orthogonal to horizontal axes/planes 62 and 68 of the frame seen in FIG. 4. Longitudinal axis 74 of frame 56 seen in FIG. 11 is configured to extend parallel to one of axes 31 and 33 of wall panel assembly 30 seen in FIG. 1 in this example.


As seen in FIG. 11A, each frame 56 includes a longitudinally-extending first portion 76. As seen in FIG. 9, the first portion of the frame is shaped to abut periphery 50 including side portion 46C of its respective wall panel 32E. Referring to FIG. 4, for fastener-hidden wall panels 32A, first portion 76 of frame 56 is shaped to also abut rear portion 48C of periphery 51 of its respective wall panel 32A and fit within recess 52 in this example. As seen in FIG. 11A, first portion 76 of frame 56 is generally a rectangular prism in outer shape in this non-limiting example.


The first portion of the frame extends substantially parallel to longitudinal axis 74 and is adjacent outer end 60 of the frame. First portion 76 of frame 56 extends from the outer end towards inner end 58 of the frame. The first portion of the frame is adjacent outer side 66 of the frame. First portion 76 of frame 56 extends from the outer side towards inner side 64 of the frame.


For each frame the first portion thereof has at least one or a first aperture or recessed portion, in this example an elongate and longitudinally-extending first recessed portion 78 extending therein. The first recessed portion extends laterally from outer side 66 towards inner side 64 of frame 56 in this non-limiting embodiment. First recessed portion 78 is adjacent and spaced from outer end 60 of the frame in this non-limiting example. For each frame the first recessed portion thereof extends longitudinally between lateral end portions 70 and 72 thereof seen in FIG. 11 in this non-limiting example. First recessed portion 78 is elongate in longitudinal and lateral profile in this non-limiting example. As seen in FIG. 9, the first recessed portion extends along or parallel to axis/plane 68 in this non-limiting example. First recessed portion 78 in lateral-section and axis/plane 68 extends substantially parallel to central portion 43 of its corresponding wall panel 32E in this non-limiting embodiment and perpendicular to side portions 46C of wall panel 32. The first recessed portion in lateral-section extends substantially parallel to outer end 60 and inner end 58 of the frame in this non-limiting embodiment. As seen in FIG. 4, first recessed portion 78 in lateral-section extends substantially parallel to rear 42 and rear portion 48C fastener-hidden wall panels 32A in this non-limiting embodiment.


As seen in FIG. 11A, each first recessed portion 78 includes a pair of inner-facing walls 80 and 82 with a series of longitudinally-extending and laterally-spaced protrusions, ridges or threading 84 thereon. As seen in FIG. 9, each frame 56 is shaped/configured to selectively couple side-fastened/fastener-exposed wall panel 32E to wall substrate 34 via at least one and in this example a plurality of longitudinally spaced fasteners 36 and 36E coupling together the frame and side portion 44C of the side-fastened wall panel. For each frame 56 first recessed portion 78 thereof is shaped to receive one or more threaded end portions 37 of the fasteners. First recessed portion 78 is shaped to receive fasteners 36E anywhere longitudinally therealong in this example.


For each frame 56 the first recessed portion thereof may be referred to as a threaded slot, fastener chase and/or screw chase in this non-limiting example. The frame may be designed in one non-limiting embodiment with an A5 thread screw chase; however, this is not strictly required. First portion 76 of frame 56 is thus configured to connect to side portion 46 of its corresponding wall panel 32. Fastener-exposed wall panels 32E thus couple to the first portion of the frame via at least fasteners 36E. The fasteners are configured to extend parallel to axis/plane 68, and/or central portion 43 of the fastener-exposed wall panel in this non-limiting embodiment.


Fasteners 36E may be made of a material or second metal that is dissimilar to that of frame 56 so as to promote a galvanic reaction which forms a slight corrosion with the mill finish frame surface. This corrosion may function to promote a locking bond that inhibits the fastener from backing out of the frame. In one non-limiting embodiment, fastener 36E is made of a stainless steel, with frame 56 being made from aluminum or an alloy thereof. The fasteners in this non-limiting example are thus made of a metal that is different from that of wall panel 32. First recessed portion 78 or screw chase may be seven-sixteenths of an inch in depth in one non-limiting embodiment so as to accommodate a fastener 36E comprising a #10, five-eighths of an inch long with A5 type thread, stainless steel self-tapping screw with countersunk Robertson drive head. Such fasteners in this non-limiting example comprise a third party product which may be purchased for example at Robertson Inc., having an address of 1185 Corporate Drive, Unit 1, Burlington, Ontario, L7L 5V5, Canada. However, this is not strictly required and other types of fasteners and sizes may be used in other embodiments.


In one non-limiting embodiment and as seen in FIG. 19, each fastener-exposed wall panel 32E (or the fastened-exposed portion of a combination fastener-exposed and fastener-hidden wall panel) has one or more apertures 39 extending through side 44 or side portion 46 thereof. As seen with reference to FIGS. 19 and 21, each aperture 39 is countersunk via a protrusion 41A pressed therein in this non-limiting example. The protrusion is frustoconical at least in part in this non-limiting example. Aligning protrusion 39A with aperture 39 as seen in FIG. 21 and thereafter biasing the protrusion towards or downwards from the perspective of FIG. 21 towards the aperture functions to deform side portion 46c of wall panel 32E and form an outwardly-facing dimpled or recessed region 39A seen in FIG. 23 extending about the aperture. The recessed region is coaxial with the aperture in this non-limiting example. Recessed region 39A is laterally outwardly-facing in this non-limiting embodiment.


The following are additional details of a non-limiting embodiment that achieves this functionality. In this non-limiting example protrusion 41A is a bit and/or part of a punching apparatus 41 seen in FIG. 19. The punching apparatus in this non-limiting embodiment comprises a hand-operated punch tool with a pair of arms 41B and 41C pivotally coupled together via a pivot 41D, with squeezing together thereof functioning to squeeze together a clamp or press 41E between which side portion 46 of wall panel is received. This process forms outwardly-facing dimpled or recessed region 39A extending about aperture 39 as seen in FIG. 23. The dimpled or recessed regions may thus be said to be formed via formed via protrusion 41A seen in FIG. 21 and/or via press, punch tool or machine in this non-limiting example. Punching apparatuses per se, such punching tools, punching machines, presses and the like, including their various parts and functionings, are known per se and punching tool 41 will accordingly not be described in further detail.


Wall panels 32E (or fastener-exposed portions thereof) seen in FIG. 9 may thus be said to include one or more side portions 46C with one or more outwardly-facing dimpled or recessed regions 39A extending therein and with each said dimpled or recessed region having aperture 39 extending therethrough. Frame 56E is threadably connectable to wall panel 32E via fastener 36E configured to extend through the aperture of the dimpled or recessed region of the side portion of the wall panel.


There may thus be provided a method of coupling wall panel 32E to wall substrate 34 comprising drilling aperture 39 seen in FIG. 21 through side portion 46C of the wall panel. The method may include forming recessed region 39A seen in FIG. 23 about the aperture via protrusion 41 seen in FIG. 21 pressed into the aperture. The method may include shaping the protrusion to be frustoconical at least in part. The method may include using punching apparatus 41 or tool to form the recessed region about the aperture. The method may include pressing protrusion 41 seen in FIG. 21 into aperture 39 so as form a countersunk said aperture. In addition or alternatively, the method may include countersinking the aperture via the protrusion pressed into the aperture. As seen in FIG. 23, this may include forming recessed region such that a fastener head 36E′ of fastener 36E is flush with side portion 46C of wall panel 32E.


The method may include threadably coupling side portion 46C of wall panel 32E to frame 56E seen in FIG. 9 via fastener 36E inserted into aperture 39. The method may include inhibiting damage to the outer layers or coatings 32.1′ and 32.1″ of wall panel 32E when countersinking aperture 39 and/or forming recessed region 39A. Thus, as the fastener is drawn into the composite skin material of wall panel 32A (which may be 4 mm thick in one non-limiting embodiment), the fastener may function to countersink until the fastener bottoms out, resulting in a desired flush finish of the fastener with the surface of the exterior skin or side portion of the wall panel for example. The method include promoting metal isolation between wall panel 32E and fastener 36E seen in FIG. 9 by countersinking the aperture and/or forming the recessed region so as to and/or in a manner which inhibits damage to said non-metal coating.


The method may thereafter include operatively connecting the wall panel to wall substrate 34 via the frame, a non-limiting embodiment of which will be described further below. For example, this may include operatively connecting the frame to the wall or wall substrate via a bracket or clip 114.


Referring to FIG. 11A, first portion 76 of frame 56, with its recessed portion 78 thereof, is thus channel-shaped and may be said to comprise a first channel 86 in this non-limiting embodiment. As seen in FIG. 9, fasteners 36E may thus be said to selectively threadably couple with the channel, with frame 56E and side portion 46C of the wall panel coupling together via the fasteners. Referring back to FIG. 11A, first channel 86 may be referred to as an outer channel of the frame. First portion 76 of frame 56 is thus C-shaped in lateral section in this non-limiting embodiment. As seen in FIG. 4, first channel 86 faces outwards towards side portions 46C of its wall panel 32A and may thus be referred to as a first outwardly-facing channel. For fastener-hidden wall panels 32A, the first channel is shaped to fit within recess 52 formed by central portion 43, rear portion 48C and side portion 46C thereof. In this manner first portion 76 of frame 56 may be said to couple to fastener-hidden wall panel 32A at least in part. As seen in FIG. 16, weep holes 53A, 53B and 53C of wall panel 32 align with and extend parallel to first portion 76. The weep holes are in fluid communication with first recessed portion 78 of frame 56.


As seen in FIG. 11A, first channel 86 has an inner closed end 86′ with an exterior or outer surface 87 which faces inner side 64 of frame 56. In this example the outer surface is angled relative to axis/plane 62 and/or axis/plane 68 seen in FIG. 4 and may be configured/positioned to promote movement of fluid thereon towards outer end 60 of the frame as seen by arrow 91 in FIG. 11A. Outer surface 87 extends substantially perpendicular to outer end 60 of frame 56 and is thus not angled in this non-limiting embodiment; however, this is not strictly required and the outer surface may be so shaped to further promote movement of fluid 89A away therefrom and/or outwards from frame 56 in other embodiments.


As seen in FIG. 15, each frame 56 has at least one and in this example a plurality of longitudinally spaced-apart apertures relative to longitudinal axis 74, in this example inner-facing apertures or slots 57, 57A and 57B. The inner-facing slots are in fluid communication with interior surface 47 of wall panel 32. Slots 57A and 57B in this non-limiting embodiment extend through inner closed end 86′ of first channel 86 of first portion 76 of frame 56. The slots extend into and are in fluid communication with first recessed portion 78. The slots may thus be said to be apertures or slots of the first portion of the frame. Slots 57A and 57B are inwardly spaced from lateral end portions 70 and 72 of frame 56 seen in FIG. 11 in this non-limiting embodiment. Referring back to FIG. 15, each slot 57 is elongate in this non-limiting embodiment, in this example being rectangular; however this too is not strictly required. Slots 57A and 57B extend about respective axes 57A′ and 57B′ which each extend substantially parallel with each other in this non-limiting embodiment. The axes of the slot extend substantially parallel to exterior surface 45 of wall panel 32 in this non-limiting example. As seen in FIG. 16, axes 57A′ and 57B′ of slots 57A and 57B extend substantially parallel to axes 53A′, 53B′ and 53C′ of weep holes 53A, 53B and 53C in this non-limiting embodiment.


As seen in FIG. 16, weep holes 53A, 53B and 53C of wall panel 32 and slots 57A and 57B of frame 56 are in fluid communication via longitudinally-extending channel 86 (including first recessed portion 78) of frame 56 in this non-limiting example. The weep holes of the wall panel and the slots of the frame are configured/positioned to promote pressure equalization. The weep holes of the wall panel are longitudinally spaced from, from the slots of the frame. Weep holes 53A, 53B and 53C and slots 57A and 57B are longitudinally aligned with in this non-limiting example. The weep holes and slots are laterally offset in this non-limiting embodiment. Weep holes 53A, 53B and 53C and slots 57A and 57B so offset/positioned may function to inhibit wind driven rain from entering through wall panel assembly 30 and/or contacting and/or spraying wall substrate 34 seen in FIG. 4.


Referring to FIG. 11A, each frame 56 includes a longitudinally-extending second portion 88 coupled to first portion 76 thereof. For each frame the second portion thereof is near or adjacent inner side 64 thereof in this example. For each frame 56, second portion 88 thereof extends from the inner side towards outer side 66 thereof. For each frame the second portion thereof is positioned between inner end 58 and outer end 60 thereof in this example.


Referring to FIG. 4, second portion 88 of frame 56 is shaped/configured to abut, receive and/or couple to rear portion 48C of fastener-hidden wall panel 32A. The second portion of the frame is configured/shaped to selectively operatively connect the rear-fastened or fastener-hidden wall panels to wall substrate 34 of building 35. In this non-limiting embodiment, this coupling is facilitated and/or occurs at least in part via at least one and in this example a plurality of longitudinally spaced-apart fasteners 36B; however, these may not strictly be required in other embodiments. The fasteners are configured to further couple together frame 56 and rear 42 and/or rear portion 48C of wall panel 32A. Second portion 88 of frame 56 is thus configured to selectively connect to the rear portion of the fastener-hidden wall panel. Wall panel 32A may thus be said to couple to the second portion of the frame via at least fasteners 36B. The following is a non-limiting embodiment which achieves this functionality.


As seen in FIG. 11A, frame 56 has a longitudinally-extending second recessed portion 90 extending within second portion 88 thereof. The second recessed portion of the frame faces outer side 66 of the frame in this example. Referring to FIG. 11, second recessed portion 90 extends between lateral end portions 70 and 72 of frame 56 in this non-limiting embodiment. As seen in FIG. 4, second portion 88 of frame 56 is shaped to receive within second recessed portion 90 thereof a distal or inner end of rear portion 48C of fastener-hidden wall panel 32A.


For each frame the second portion thereof with its recessed portion 90, may thus be said to be channel-shaped and comprise a longitudinally-extending second channel 92 in this example. The second channel may be referred to as an intermediate or middle channel of the frame. Second portion 88 of frame 56 is thus C-shaped in lateral section in this non-limiting embodiment. The second channel extends substantially parallel to first channel 86 of the frame and axis/plane 68 in this non-limiting example. As seen in FIG. 11A, second channel 92 is laterally offset relative to first channel 86 in this example. The second channel is closer to inner side 64 of frame 56 compared to the first channel and may thus be said to be inwardly positioned from the first channel relative to wall panel 32A seen in FIG. 4. Channels 86 and 92 are integrally coupled together so as to form a unitary whole in this non-limiting example. Second channel 92 couples to and extends laterally outwards from inner closed end 86′ of first channel 86 in this non-limiting example.


As seen in FIG. 11A, second channel 92 adjacent inner closed end 92′ thereof, has a first exterior or outer surface 93A that is shaped to promote dispersal of fluid 89B away therefrom and/or outwards from frame 56 parallel to axis/plane 68. In this example the first outer surface is angled to this end, in this case being angled slightly relative to axis/plane 62 and/or axis/plane 68 seen in FIG. 4, in this non-limiting example by about 3 degrees. Referring back to FIG. 11A, first outer surface 93A of inner closed end 92′ of second channel 92 may be configured/positioned to promote movement of fluid 89B thereon towards outer end 60 of frame 56 as seen by arrow 95. Thus if fluid 89B is on surface 93A so angled, frame 56 is shaped to promote movement of the fluid in the direction indicated by arrow 91 via gravity downwards onto surface 87 and from there, the fluid may pass through one of slots 57 seen in FIG. 15 and thereafter exit via one of weep holes 53 seen in FIG. 16. Referring back to FIG. 11A, first outer surface 93A of second channel 92 so angled may therefore function to divert water to where the machined slots are the lowest point to enable the water to pass through first recessed portion 78 of the frame and drain/exit through the offset weep holes. The first recessed portion of the frame may be referred to as a drainage gutter cavity.


As seen in FIG. 11A, for each frame 56 second portion 88 thereof has a second outer or exterior surface 93B which faces towards outer end 60. The second exterior surface is configured/positioned to promote movement of fluid 89C thereon towards the outer end of the frame as seen by arrow 95 in FIG. 11A. To achieve this functionality, second exterior surface 93B may comprise a vertical drop and/or be angled relative to axis/plane 62 and/or axis/plane 68 seen in FIG. 4 for example.


As seen in FIG. 3, for each frame 56 second portion 88 (or channel 92) thereof has at least one and in this example a plurality of longitudinally-spaced sets of second apertures 85A and 85B extending therein. As seen in FIG. 4, each set of second apertures 85A and 85A.1 is axially in this non-limiting example via which fastener 36B extends and/or threadably couples thereto as well as to rear portion 48C of fastener-hidden wall panel 32A. However, this is not strictly required and only one aperture 85A may be provided in other embodiments. Apertures 85A.1 extend through second exterior surface 93B of second channel 92 seen in FIG. 11A. Referring back to FIG. 3, sets of second apertures 85A and 85B extend along or parallel to axis/plane 62. The second apertures extend parallel to side 44C and/or side portion 46C of wall panel 32A. Fasteners 36B are configured to extend parallel to side 44C or side portion 44C of wall panel 32A and axis/plane 62 and/or perpendicular to central portion 43 of the wall panel in this non-limiting embodiment. Rear portion 48C or leg of wall panel 32A is thus insertable into the designed frame pocket or channel 92 of frame 56, with fastener 36B thereafter attaching through the frame, the wall panel and backside of the frame. There may be an alignment mark (not shown) for the fastener location on the frame; however, this is not strictly required.


Referring to FIGS. 4 and 9, frame 56 as herein described is thus selectively connectable to rear-fastened/fastener-hidden wall panel 32A seen in FIG. 4, side-fastened/fastener-exposed wall panel 32E seen in FIG. 9 or a combination fastener-hidden and fastener-exposed wall panels 32I and 32L seen in FIG. 18 via one or more fasteners 36. There are thus two modes of attaching frames 56 to the wall panels: i) a first mode for fastener-exposed wall panels 32E and 32F seen in FIG. 9 or one or more sides, in this non-limiting example top sides 44B of combination fastener-hidden and fastener-exposed wall panels 32I/32J/32K/32L seen in FIGS. 18, where each said wall panel includes on the referenced side thereof a single return and exposed fastener 36E/36F/36I coupled thereto as seen in FIGS. 9 and 18; and ii) a second mode for fastener-hidden wall panels 32A and 32B seen in FIG. 4 or one or more sides, in this non-limiting example side portions 44A and 44B and bottom sides 44D of combination fastener-hidden and fastener-exposed wall panels 32I/32J/32K/32L seen in FIGS. 18, where each said wall panel has on the referred side thereof a double return with concealed fastener 36A/36B/36L coupled thereto seen in FIGS. 4 and 18.


As seen in FIG. 11A, frame 56 includes a longitudinally and laterally-outwardly extending flange 94 positioned between inner end 58 and outer end 60 thereof. The flange extends from inner side 64 towards outer side 66 of the frame in this non-limiting embodiment. Flange 94 is a rectangular prism in shape in this non-limiting example. As seen in FIG. 4, each flange is shaped to couple to and extend inwards (relative to panel 32A) from closed inner end 92′ of second channel 92 to inner end 58 of frame 56. Flange 94 extends substantially parallel to second portion 88, second channel 92 and axis/plane 68 of frame 56 in this non-limiting example. As seen in FIG. 11A, the flange is shaped to inhibit fluid from moving from inner end 58 to outer end 60 of frame 56 and vice versa. The frame (including flange 94 thereof) is shaped to promote movement of fluid positioned laterally in a first or right direction 91 relative to flange 94 from the perspective of FIG. 11A, towards outer end 60 thereof. The frame (including the flange thereof) is shaped to promote movement of fluid positioned laterally in a second or right direction 95 relative to the flange from the perspective of FIG. 11A, towards inner end 58 thereof. Channel 92 inhibits fluid communication between channels 86 and 100.


Flange 94 has a longitudinally-extending first, outer-facing or outer surface 94A facing outer end 60 of frame 56. The first outer surface of the flange may be shaped to promote movement of fluid 89D thereon towards the outer end of the frame in one non-limiting embodiment. Flange 94 has a longitudinally-extending second, inner-facing or inner surface 94B facing inner end 58 of frame 56. The inner surface of the flange may be shaped to promote movement of fluid 89E thereon towards the inner end of the frame in one non-limiting embodiment. Surfaces 94A and 94B of flange 94 are rectangular in this non-limiting example. Still referring to FIG. 11A, for each frame 56 exterior surfaces 87, 93A, 93B and 94A thereof between outer end 60 and longitudinal axis 74 thereof are thus shaped to promote movement of fluid 89A, 89B, 89C and 89D towards the outer end thereof in this non-limiting embodiment. Wall panel assembly 30 as herein described may thus be referred to as a rainscreen panel assembly.


Still referring to FIG. 11A, frame 56 in this non-limiting embodiment includes a longitudinally-extending third portion 96. As seen in FIG. 11, for each frame the third portion thereof in this non-limiting example extends between lateral end portions 70 and 72 thereof. Referring back to FIG. 11A, third portion 96 of frame 56 is adjacent inner end 58 of the frame in this non-limiting example. The third portion of the frame extends from the inner end towards outer end 60 of the frame in this non-limiting embodiment. Third portion 96 of frame 56 is adjacent outer side 66 of the frame in this non-limiting example. The third portion of the frame extends from the outer side towards inner side 64 of the frame in this non-limiting embodiment.


Frame 56 has a longitudinally-extending third recessed portion 98 extending within third portion 96 thereof. As seen in FIG. 4, the third recessed portion is triangular or wedge shaped in lateral section in this non-limiting embodiment. Third portion 96 includes a longitudinally-extending first or inner sub-portion 97 which aligns with inner end 58 of frame 56. The inner sub-portion of the third portion of the frame extends substantially parallel to axis/plane 68 seen in FIG. 4 in this non-limiting embodiment. Inner sub-portion 97 may be referred to as an inner portion of frame 56 configured to be adjacent or near wall substrate 34. Referring back to FIG. 11A, third portion 96 of frame 56 includes a longitudinally-extending second or outer sub-portion 99. The outer sub-portion is shaped to selectively flex and/or be resilient at least in part.


Third portion 96 of frame 56, with third recessed portion 98 thereof, is thus channel-shaped or comprises a third channel 100 of the frame in this example defined by sub-portions 97 and 99 thereof. The third channel of the frame may be referred to as an inner channel of the frame. Each of channels 86, 92 and 100 faces outer side 66 of frame 56 in this example as seen in FIG. 11A. Third channel 100 extends at least in part parallel to first channel 86, second channel 92 and axis/plane 68 of the frame in this non-limiting example. The third channel in lateral section aligns relative to axis/plane 62 with the first channel in this non-limiting embodiment. Third portion 96 of frame 56 may be said to be C-shaped in lateral section in this non-limiting embodiment. Longitudinally-extending frame 56, with its first portion 76, second portion 88 and third portion 96 each being C-shaped in lateral section, may thus be said to comprise a plurality of C-shapes, in this case three C-shapes in lateral section each facing the same direction, in this example towards outer side 66 thereof.


Third channel 100 is laterally outwardly positioned from second channel 92 relative to its wall panel 32A in this non-limiting embodiment. Channels 92 and 100 are integrally coupled together so as to form a unitary whole in this non-limiting example. The second channel couples to and extends substantially parallel to axis/plane 68 from inner closed end 100′ of the third channel in this non-limiting example.


As seen in FIG. 11A, exterior or outer surface 101 of frame 56 extending along/adjacent inner closed end 100′ of third channel 100 is shaped to disperse/direct fluid 89F away therefrom and/or outwards from the frame. In this example the outer surface is angled to this end, in this case being slightly angled relative to axis/plane 62 and/or axis/plane 68 seen in FIG. 4 (in this non-limiting embodiment by about 2 degrees). Outer surface 101 of inner closed end 100′ of third channel 100 of frame 56 may be configured/positioned to promote movement of fluid thereon towards inner end 58 of the frame as seen by arrow 95 in FIG. 11A. Still referring to FIG. 11A, for each frame 56 exterior surfaces 94B and 101 thereof between the inner end and longitudinal axis 74 thereof are thus shaped to promote movement of fluid 89E and 89F towards the inner end thereof in this non-limiting embodiment. Surface 101 so angled may function to inhibit or prevent pooling water from standing or remaining on the frame.


Frame 56 as herein described thus comprises a plurality of longitudinally-extending channels 86, 92 and 100 with exterior surfaces 87, 93A, 93B, 94A, 94B and 101 thereof shaped to angle fluid 89A, 89B, 89C, 89D and 89E away therefrom and/or outwards from the frame. The frame thus includes three channels each facing outer side 66 thereof. Frame 56 may thus be said comprise a plurality of sloped surfaces along the exterior thereof and which configured to divert water and inhibit pooling of water. Inner side 64 of frame 56 is thus shaped to inhibit pooling of fluid thereon. Frame 56 may thus be said to have exterior surfaces 87, 93A, 93B, 94A, 94B and 101 along the inner side thereof, where the exterior surfaces are shaped to angle fluid away therefrom and outwards from the frame. Said exterior surfaces along inner side 64 of the frame extend from inner end 58 to outer end 60 of the frame.


Exterior surfaces 87, 93A, 93B, 94A, 94B and 101 along the inner side of the frame 56 comprise a plurality of L-shapes in lateral profile in this non-limiting embodiment. The frame along inner side 64 thereof may thus be said to comprise a first or inner L-shaped bracket portion (including surfaces 94B and 101) facing inner end 58 thereof and a second or outer L-shaped bracket portion (including surfaces 87 and 93B) facing outer end 60 thereof. Frame 56 may be said to include a third or intermediate L-shaped bracket portion (including surfaces 93A and 94A) facing one of the inner and outer ends thereof, in this example the outer end, with the third or intermediate L-shaped bracket portion extending between, coupling together, and laterally outwardly positioned relative to the first or inner L-shaped bracket portion and the second or outer L-shaped bracket portion. The frame along inner side 64 thereof, may thus be said to comprise a first one or more steps (including surfaces 94B and 101) which direct fluid thereon to inner end 58 thereof and a second one or more steps (including surfaces 94A, 93A, 93B and 87) which direct fluid thereon to outer end 60 thereof.


Still referring to FIG. 11A, sub-portion 99 of third portion 96 of frame 56 is angled in lateral section relative sub-portion 97 of the third portion of the frame in this example. Third channel 100 of the frame is V-shaped in lateral profile in this non-limiting embodiment. The third channel includes a distal end portion 102 that is enlarged. The distal end portion of the third channel is a part of outer sub-portion 99 of third portion 96 of frame 56. Distal end portion 102 of third channel 100 tapers towards outer side 66 of frame 56 in this example. The distal end portion of the third channel is generally a triangular prism in this non-limiting embodiment. Distal end portion 102 of third channel 100 has a pair of angled longitudinally-extending inner surface 104 and outer surface 106 which flare outwards from outer side 66 towards inner side 64 of the frame in this non-limiting embodiment. Each of the surfaces of the distal end portion of the third channel is angled in this non-limiting embodiment. Each surface 104 and 106 is planar and rectangular in profile in this non-limiting example.


Still referring to FIG. 11A, third channel 100 includes a longitudinally-extending catch 108 positioned along distal end portion 102 thereof in this example. The catch includes a longitudinally-extending shoulder 108A in this example. The shoulder extends in part in a direction extending from inner end 58 towards outer end 60 of frame 56. Shoulder 108A of catch 108 is shaped to enclose third channel 100 in part. Inner surface 104 of distal end portion 102 of third channel 100 extends/tapers outwards from the shoulder of the catch towards outer side 66 of frame 56. A recessed portion 108B is formed between inner closed end 100′ of the third channel and shoulder 108A of catch 108. The recessed portion may be referred to as a seat.


As seen in FIG. 9, channels 86, 92, and 100 of respective adjacent pairs of frames 56A and 56B from respective adjacent pairs of wall panels 32A and 32B are configured to face each other in this non-limiting example.


As seen in FIG. 1, wall panel mount system 54 (and/or wall panel assembly 30 thereof) includes at least one and in this example a plurality of elongate planar members, in this non-limiting embodiment slats, in this case splines 110. Each spline may be made of the same/similar material as from panels 32 in one non-limiting embodiment. Splines 110 may be comprise leftover material from the manufacture of the panels for example; however, this is not strictly required. Referring to FIG. 4, each spline 110 may be made or formed from surface stock material to infill distances or reveals 135 between adjacent wall panels 32A and 32B.


As seen in FIG. 3, the splines in this non-limiting embodiment comprise a row of splines 110A, 110B and 110C between which extend first row R1 of wall panels 32A and 32B and second row R2 of wall panels 32C and 32D, respectively. The splines in this non-limiting embodiment comprise a plurality of columns of splines, with each column comprising one or more splines. This is seen by 1) first column of splines 110D, 110E and 110F extending between splines 110A and 110B and between which are positioned wall panels 32A and 32B; and 2) second column of splines 110G, 110H and 110I extending between splines 110B and 110C and between which are positioned wall panels 32C and 32D. However, this arrangement is not strictly required and the splines may be arranged in other manners in other embodiments.


As seen in FIG. 4, each spline has a width W5 which extends parallel to axis/plane 68. The width of the spline may be one and half inches in one non-limiting embodiment; however, this is not strictly required. Each spline 110 is configured to cover or hide from view at least in part the rest of the wall mount system positioned therebehind, including frames 56A and frames 56B thereof, when viewed from exterior 38. Each spline is configured to extend along and adjacent or near to at least one respective side 44 and side portion 46 of a corresponding wall panel 32.


Each spline 110 is rectangular in longitudinal and lateral view and a rectangular prism in shape in this non-limiting embodiment. Each spline 110E is shaped to abut and extend perpendicular to side portions 46 of wall panels 32 in this example. The splines arranged between rows of wall panels 32A and 32B are positioned to extend parallel to axis/plane 68 in this example. When positioned between adjacent wall panels, spline 110E is configured to be positioned between second channels 92 and third channels 100 of respective wall panels 32A and 32B in this non-limiting example. Each spline is configured to expose a third or half of a longitudinal-extending portion 110′ thereof to exterior 38 in this non-limiting embodiment, with the rest of the spline overlapping with frame(s) 56. For fastener-hidden panels, splines 110E are configured to abut and extend parallel to rear portions 48C and 48A of adjacent wall panels 32A and 32B.


As seen in FIG. 9, distal end portion 102 of each third channel 100 of each frame 56A so tapered, including outer surface 106 thereof, is shaped to facilitate slidable insertion of spline 110E between periphery 50 of wall panel 32A and third channel 100 of the frame.


Referring to FIG. 5, splines 110 are additionally shaped to extend between frame 56 and adjacent wall 112 extending outwards from wall substrate 34. In this case the spline may be shaped to abut the wall and extend across the gap or distance D otherwise formed between the wall and frame/wall panel 32.


As seen in FIG. 3, wall panel mount system 54 includes at least one and in this example a plurality of connectors, in this case: a first plurality of first, central, primary or full clips 114 and; a second plurality of second, side, auxiliary or half clips 114.1. The clips as herein described may be referred to as mounting brackets.


For clips 114 and 114.1, unless the context clearly requires otherwise, like parts have like numbers and functions with the addition of decimal extension “0.1”. As seen in FIG. 4, each full clip is configured to selectively couple together adjacent frames 56A and 56B, in this non-limiting example via a snap-fit connection. Half clip 114.1 seen in FIG. 5 also uses a snap-fit connection to selectively couple wall panel 32 via frame 56 to wall substrate 34, and is configured to be used: at perimeter panel conditions where a full clip cannot be used; for applications where a wall panel removal and reinstallation is required; and/or to install a missing wall panel from the field area of a completed wall (such that scaffolding tie backs are required for example). The following is a non-limiting embodiment which achieves the above set out functionality.


As seen in FIG. 13, each clip 114 is resilient at least in part. In this non-limiting embodiment each clip is made of metal, in this non-limiting example steel, in this non-limiting case a stainless steel, in this particular instance 304 stainless steel; however, this is not strictly required and the clips may be made of other metals or materials in other embodiments. Each clip in this non-limiting embodiment made of a planar member, in this case metal sheet which is formed/bent into shape; however, this is not strictly required. The full clip comprises a metal sheet that is folded over on itself in this non-limiting embodiment. Each clip 114 is generally rectangular in planar profile in this example; however, here too this is not strictly required. Each clip in this non-limiting example is punched and formed into full and half clips 114 and 114.1 seen in FIGS. 13 and 14, respectively.


Referring to FIG. 4, each clip 114 includes at least one portion thereof shaped to selectively couple to frame 56. Each clip in this example snap-fit connects to a corresponding frame. The following is a non-limiting embodiment which achieves this functionality.


Each clip 114 includes a first folded portion 116 via which the clip selectively couples and in this example snap-fit connects to its corresponding frame 56. Portion 116 may be referred to as a V-shaped bracket or bracket portion of the clip and may be formed without bending in other embodiment. First folded portion 116 of clip 114 may be referred to as a first folded end portion, a first male portion and/or a clip snap interface. The first folded portion of the clip may be referred to as a resilient portion shaped to snap-fit connect with a frame of the wall panel mount system. First folded portion 116 of clip 114 is shaped to be selectively received within channel 100 of frame 56A so as to couple to third portion 96 of the frame. Third recessed portion 98 may be referred to as a female portion shaped to receive a respective male portion or portion 116 of clip 114. Each frame 56A may thus be said to include an inner or third channel 100 with one or more angled surfaces thereof (e.g. surface 104 or surface 108B′) shaped to facilitate insertion of the clip therein, with the angled surfaces being angled relative wall panels 32A and 32B and/or wall substrate 34.


Each frame 56A may thus be said to include an inner or third channel 100 with one or more angled surfaces thereof (e.g. surface 104 or surface 108B′) shaped to facilitate insertion of the clip therein, with the angled surfaces being angled relative wall panels 32A and 32B and/or wall substrate 34. Thus and referring to FIG. 5, channel 100 may be said to have a first angled surface 104 along which a first side or surface 107A of clip 114.1 is slid towards the channel. The channel may be said to have a second surface 98′ opposite surface 104, with the second surface of the channel abutting a second side or surface 107B of the clip opposite the first side or surface of the clip as the clip is inserted into the channel and functioning to straight the clip out as the clip further enters the channel. First and second surfaces 107A of clip 114.1 are surfaces of first folded portion 116.1 of the clip in this non-limiting example.


The first folded portion of the clip is V-shaped in lateral profile in this non-limiting example and is formed by bending a first end portion 118 of clip 114 seen in FIG. 12 over itself at least in part. First folded portion 116 of clip 114 comprises a pair of planar members, in this example sub-portions 116A and 116B which are rectangular in profile in this example. Sub-portion 116A couples to and extends outwards from sub-portion 116B at an acute angle α relative thereto. First folded portion 116 of clip 114 is inwardly deformable.


Referring back to FIG. 4, distal end portion 102 of third channel 100 so tapered, including its inner surface 104 thereof, is shaped to facilitate insertion of first folded portion 116 of the clip within the third channel of the frame. First end portion 118 of clip 114 is shaped to fit within recessed portion 108B and abut shoulder 108A of catch 108, with the clip snap-fit coupling to frame 56A thereby. The clip engages the frame with a snap fit, with the frame (including sub-portion 99 of third portion 96 thereof) being configured to flex at least in part to allow/enable the clip to interface therewith. The clip is thus fixedly coupled to frame 56A. First folded portion 116 of clip 114 in this non-limiting example may also substantially extend along and frictionally engages with interior surface 100A of third channel 100 seen in FIG. 11A.


As seen in FIG. 12, first folded portion 116 of clip 114 has at least one and in this example a pair of apertures 120 and 121 extending therethrough. The apertures of the first fold portion of the clip align axially with each other. Clip 114 includes an additional aperture 122 which aligns with apertures 120 and 121 when the clip is in its folded position seen in FIG. 13.


Referring to FIG. 4, first folded portion 116 of clip 114 in this non-limiting embodiment additionally fixedly couples to frame 56A via one or more fasteners, in this example a fixing point fastener 124. Referring to FIGS. 4 and 13, the fastener first extends through aperture 122, next pierces through inner sub-portion 97 of third portion 96 of frame 56, and then extends into aperture 120 and 121 last, stopping short of distorting angle leg or sub-portion 99 of the third portion of the frame in this non-limiting example. Fastener 124 thus further couples together the third portion of the frame and the first folded portion of the clip. The fastener may comprise a fixing point screw in one non-limiting example. As seen in FIG. 4, clip 114 so configured and coupled to frame 56A, is thus inhibited from moving longitudinally relative to frame 56A and/or wall panel 32A. The clip is thus configured to fixedly couple to frame 56A. For each clip 114 apertures 120, 121 and 122 seen in FIG. 13 may be referred to additional holes thereof at the backside 123 of the clip and which extend through all three layers to accommodate fixing point fastener 124 seen in FIG. 4. The backside of the clip faces wall substrate 34 of building 35.


Still referring to FIG. 4, full clip 114 is configured to slidably couple to second frame 56B. The following is a non-limiting embodiment which achieves this functionality. Full clip 114 includes a second portion thereof, in this non-limiting embodiment a second folded portion 126, via which the clip slidably couples to second frame 56B. The second folded portion of the full clip may be referred to as a second folded end portion, a second male portion and/or clip slide function interface. For each full clip 114 second folded portion 126 thereof is laterally spaced relative to axis/plane 68 from first folded portion 116 thereof. The second folded portion is shaped to be slidably received within and slidably couple to third channel 100B of second frame 56B. Second folded portion 126 is shaped to slidably extend along and abut sub-portion 97 of third portion 96 of the frame seen in FIG. 11A.


As seen in FIG. 12, full clip 114 is formed in this non-limiting embodiment via two halves 128A and 128B which are at least in part similar in shape and which are foldable over themselves (as seen by the direction indicated by arrow 130) so as to form second folded portion 126 thereof. The clip may thus be said to comprise male or folded portions 116 and 126 formed by moving the clip from an at least partially planar or unfolded position seen in FIG. 12 to the folded position seen in FIG. 13. However, this is not strictly required and portion 126 may not be folded in other embodiments, for example. Halves 128A and 128B of full clip 114 couple together via one or more spaced-apart tabs 132A and 132B configured to couple the halves together while facilitating bending thereof by hand by the installer of the wall panels, for example. Second folded portion 126 comprises a pair of planar members, in this example sub-portions 126A and 126B which are rectangular in profile in this example. The sub-portions of the second folded portion of clip 114 couple together and are bendable relative to each other via tabs 132A and 132B in this example; however, the latter is not strictly required. The clip is folded by the installer as it may be easier to insert (snap fit) the clip into place when the clip is first unfolded. In other words, if the clip is provided to the installer in a pre-folded configured, it may not interface with the frame as easily. However, this is not strictly required and the clip(s) may be provided in pre-folded configuration in other embodiments.


Referring back to FIG. 4, full clip 114 is thus configured to snap-fit to frames 56A and 56B via third channels 100 and 100B of the frames. The full clip in this non-limiting example thus couples to the third channels of the frames via a pair of spaced-apart folded portions 116 and 126 thereof. Full clip 114 thus extends within channels 100 and 100B via the pair of spaced-apart folded portions thereof, within movement of the clip in a direction parallel to axis/plane 68 being inhibited thereby.


As seen in FIG. 4, second folded portion 126 of the clip and/or third channel 100B are shaped to provide a gap or cavity clearance 134 therewithin extending between the distal end 126C of the second folded portion end and closed/interior end 100C of the third channel. This may function to enable wall mount system 54 to expand due to changes in temperature or the like, which may otherwise cause some shifting of panels 32A and 32B. Clip 114 as herein described (including clip interface 114A thereof seen in FIG. 13 and spanning between folded portions 118 and 126 thereof) is thus designed to hold/couple-snugly with frame 56A while accommodating of any forced sliding movement from thermal expansion and contraction or the like. In one non-limiting embodiment, the distance or reveal 135 between side portions 44C and 44A of adjacent wall panels 32A and 32B may be one half inch which allows for a one-eighth of an inch cavity clearance for expansion. Clip interface 114A seen in FIG. 13 may comprise seven-sixteenths of an inch, so with one-eighth of an inch contraction, there may still be five-sixteenths of an inch of clip interface connection in one non-limiting embodiment. As seen in FIG. 2, each installed wall panel 32A in this non-limiting embodiment includes at least one fixing point clip 114 on two adjacent sides and the remainder of clips are non-fixed, thereby allowing the frame to slide in the clip freely with thermal expansion and contraction.


As seen in FIG. 5, half clip 114.1 has no such second folded portion and does not include halves which fold on themselves in this non-limiting example.


Referring back to FIG. 4, full clip 114 in this non-limiting embodiment includes a protrusion 136 positioned between adjacent frames 56A and 56B. The protrusion for the full clip in this non-limiting example is an inverse U-shaped in lateral profile. Protrusion 136 is positioned between folded portions 116 and 126 of the clip. As seen in FIG. 13, for each full clip the protrusion thereof comprises in this non-limiting example third and fourth folded portions 136A and 136B thereof which are configured to fold on themselves and/or nest with each other. Folded portion 136A may be referred to as a first of a ridge and trough and folded portion 136B may be referred to as a second of a ridge and trough. As seen in FIG. 9, protrusion 136 of full clip 114 is shaped to extend laterally outwards parallel to axis/plane 62 past inner end 58 of frames 56A and 56B. A central portion 141 of the protrusion (including folded portion 136A thereof) is planar and shaped to extend along, flush with and abut wall substrate 34 of building 35 in this example. Protrusion 136 may be referred to as a first ledge or support of full clip 114.


As seen in FIG. 13, each full clip has at least one and in this example a single longitudinally spaced aperture 137 extending through protrusion 136 thereof. The apertures extend parallel to plane/axis 62 seen in FIG. 9 in this example. Still referring to FIG. 9, full clip 114 is configured to selectively couple to wall substrate 34 via one or more fasteners, in this example fasteners 139 extending through the apertures of protrusion 136 and extending into the wall substrate. The full clip is thus shaped to mount adjacent pairs of wall panels 32E and 32F to wall substrate 34 by snap-fit connecting together adjacent pairs of frames 56A and 56B, each in turn connected to a respective said wall panel. Aperture 137 seen in FIG. 13 may thus be referred to as one hole near the center or central portion 141 of clip 114 for attachment back to building 35 or wall substrate 34 thereof.


As seen in FIG. 5, half clip 114.1 terminates with folded portion 136A.1 and is L-shaped in lateral section in this non-limiting example. As seen in FIG. 14, portion 136A.1 of the half clip has aperture 137.1 extending therethrough which is obround in this non-limiting embodiment; however, this is not strictly required.


As seen in FIG. 9, full clip 114 includes a second protrusion or ledge 138 shaped to abut wall substrate 34 of building 35. As seen in FIG. 12, the ledge is adjacent a second end portion 143 of the clip which is spaced-apart form first end portion 118 of the clip. The second ledge is laterally spaced from protrusion 136 relative to axis/plane 68 in this example. Ledge 138 is L-shaped in lateral section in this example and may be referred to as an L-shaped bracket or bracket portion of clip 114 shaped to abut the wall or wall substrate. As seen in FIG. 9, full clip 114 is formed by one or more additional bends, in this non-limiting example: a first bent portion 140 which causes the clip to enclose therewithin and/or extend-along/substantially-parallel-to inner sub-portion 97; a second bent portion 142 which redirects the clip so as to cause the clip to enclose and/or extend-along/substantially-parallel to at least in part outer surface 101 of inner closed end 100′ of third channel 100; a third bent portion 144 which re-directs the clip towards wall substrate 34; and a fourth bent portion 146. The first, second and fourth bent portions of the full clip are L-shaped in lateral profile and the third bent portion of the full clip is U-shaped in lateral profile in this non-limiting embodiment. Fourth bent portion 146 of full clip 114 corresponds to second end portion 143 of the full clip and is shaped to abut, and extend along and substantially parallel to wall substrate 34 of building 35. Third bent portion 144 may be said to comprise a ledge for dead load support of frame 56E and/or frame 56F.


As seen in FIG. 9, full clip 114 thus substantially extends along, abuts and/or frictionally engages at least in part outer and inner surfaces of third channel 100 of first frame 56E in this non-limiting example. The full clip is thus shaped to fold about inner and outer surfaces of the first frame in this non-limiting embodiment. Referring to FIG. 4, clip 114 may thus be said to extend along and/or wrap backside(s) 115 and 115A of frame 56A. The backsides of the frames face wall substrate 34 of building 35 at least in part and may be said to parts of third portions 96 of the frames. Clip 114 may thus be said to enclose the inner portion or inner sub-portion 97 of frame 56E and slidably couple to the inner portion or inner sub-portion of frame 56F.


Referring to FIG. 13, exterior surface 117 of clip 114 in this non-limiting embodiment includes a protective membrane thereon made of an insulating and/or non-metal material, in this non-limiting example a polymer, in this case protective plastic foil 119. The protective plastic foil may be mill-installed, though this is not strictly required. Protective plastic foil 119 may function to isolate frames 56A and 56B and clip 114 seen in FIG. 4 where the frames and clip are made of dissimilar metals: for example, where the frames are made aluminum and the clip is made of stainless steel.


Referring to FIG. 4, there is accordingly provided a method of coupling a pair of wall panels 32A and 32B to wall substrate 34 according to one aspect. The method includes coupling a pair of frames 56A and 56B to respective ones of the wall panels. The method includes folding metal sheet 114′ at least in part as seen with reference to FIGS. 12 and 13. The method may include within the folding step, folding the metal sheet so as to form a clip. Referring back to FIG. 4, the method includes fastening the metal sheet so folded to wall substrate 34, in this non-limiting example via fasteners 139. The method includes coupling frames 56A and 56B to the wall substrate via metal sheet 114′ so folded, in this non-limiting example via folded end portions 116 and 126 and fasteners 124. The method may include within the coupling the frames to the wall or wall substrate step, shaping the metal sheet so folded to snap-fit couple to a first said frame and slidably couple to a second said frame.


Still referring to FIG. 4, there may thus also be provided a method of coupling a pair of wall panels 32A and 32B to wall substrate 34 according to another aspect. The method includes coupling first and second frames 56A and 56B to respective ones of the wall panels 32A and 32B. This may be in the manner shown/described with respect to FIG. 4 or 9 with fasteners 36B, 36E and 36F, for example. The method includes fastening clip 114 to wall substrate 34. This may be for example via fastener 139. The method may include inserting the male portions or portions 116 and 126 of clip 114 into female portions or recessed portions 98 of the frames so as to snap-fit connect to frame 56A and slidably couples to frame 56B.


As seen in FIG. 4, there is thus further provided a method of installing wall panel assembly 30 on wall substrate 34 according to an additional aspect. The method includes coupling a first plurality of frames 56A and 56B to rear portions 48C of a first set of wall panels 32A and 32B having peripheries 51 that are C-shaped in lateral section. The method may include within the step of coupling the first plurality of frames to the first set of wall panels: providing the frames with longitudinally-extending first portions or channels shaped to snugly fit within respective C-shaped peripheries of the first set of wall panels. Referring to FIG. 9, the method includes coupling a second plurality of frames 56E and 56F to side portions 44A and 44C of a second set of wall panels 32E and 32F having peripheries 50 that are L-shaped in lateral section. The method includes mounting the wall panels to wall substrate 34 via a plurality of clips 114 which selectively couple to the frames so coupled thereto. The method may include within the mounting step: mounting the first set of wall panels on a lower portion of the wall; and mounting the second set of wall panels on an upper portion of the wall.


Wall mount system 54, which may be referred to as kit for wall panels 32, accordingly comprises a plurality of frames 56, 56A, 56B, 56C and 56D seen in FIG. 3 as herein described and a plurality of clips 114 and 114.1 as herein described for installing and facilitating installation of both fastener-hidden wall panels 32A, 32B, 32C and 32D seen in FIG. 1 and fastener-exposed wall panels 32E, 32F, 32G and 32H seen in FIG. 6 to a wall or wall substrate of a building. Wall panel assembly 30 is different from the wall mount system in that the wall panel assembly may comprise: i) both the wall mount system and wall panels 32 or ii) only the wall panels, with the wall mount system being used to mount the wall panel assembly to the wall or wall substrate.


It will be appreciated that many variations are possible within the scope of the invention described herein. For example, while FIG. 1 shows fastener-hidden or rear-fastened wall panels 32A, 32B, 32C and 32D and FIG. 6 shows fastener-exposed or side-fastened wall panels 32E, 32F, 32G and 32H, as a further alternative, a wall panel may have both side and rear connections on the same panel. For example, for such a wall panel the vertical edges or side portions 46A and 46C thereof may be fastener-exposed/side-fastened and the horizontal edges or side portions 46B and 46D thereof may be fastener-hidden/rear-fastened. As a further non-limiting embodiment, the top horizontal edge or side portion 46B may be fastener-exposed/side-fastened and the other side portions 46A, 46C and 46D may be fastener-hidden/rear-fastened, for example. It will be appreciated that yet further variations or combinations are also possible.


Where a component (e.g. a member, apparatus, assembly etc.) is referred to herein, unless otherwise indicated, reference to that component (including a reference to a “means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.


Interpretation of Terms

Unless the context clearly requires otherwise, throughout the description and the claims:

    • “comprise”, “comprising”, and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”;
    • “connected”, “coupled”, or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling or connection between the elements can be physical, logical, or a combination thereof;
    • “herein”, “above”, “below”, and words of similar import, when used to describe this specification, shall refer to this specification as a whole, and not to any particular portions of this specification;
    • “or”, in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list;
    • the singular forms “a”, “an”, and “the” also include the meaning of any appropriate plural forms. These terms (“a”, “an”, and “the”) mean one or more unless stated otherwise;
    • “and/or” is used to indicate one or both stated cases may occur, for example A and/or B includes both (A and B) and (A or B);
    • “approximately” when applied to a numerical value means the numerical value ±10%;
    • where a feature is described as being “optional” or “optionally” present or described as being present “in some embodiments” it is intended that the present disclosure encompasses embodiments where that feature is present and other embodiments where that feature is not necessarily present and other embodiments where that feature is excluded. Further, where any combination of features is described in this application this statement is intended to serve as antecedent basis for the use of exclusive terminology such as “solely,” “only” and the like in relation to the combination of features as well as the use of “negative” limitation(s)” to exclude the presence of other features; and
    • “first” and “second” are used for descriptive purposes and cannot be understood as indicating or implying relative importance or indicating the number of indicated technical features.


Words that indicate directions such as “vertical”, “transverse”, “horizontal”, “upward”, “downward”, “forward”, “backward”, “inward”, “outward”, “left”, “right”, “front”, “back”, “top”, “bottom”, “below”, “above”, “under”, and the like, used in this description and any accompanying claims (where present), depend on the specific orientation of the apparatus described and illustrated. The subject matter described herein may assume various alternative orientations. Accordingly, these directional terms are not strictly defined and should not be interpreted narrowly.


Where a range for a value is stated, the stated range includes all sub-ranges of the range. It is intended that the statement of a range supports the value being at an endpoint of the range as well as at any intervening value to the tenth of the unit of the lower limit of the range, as well as any subrange or sets of sub ranges of the range unless the context clearly dictates otherwise or any portion(s) of the stated range is specifically excluded. Where the stated range includes one or both endpoints of the range, ranges excluding either or both of those included endpoints are also included in the invention.


Certain numerical values described herein are preceded by “about”. In this context, “about” provides literal support for the exact numerical value that it precedes, the exact numerical value ±5%, as well as all other numerical values that are near to or approximately equal to that numerical value. Unless otherwise indicated a particular numerical value is included in “about” a specifically recited numerical value where the particular numerical value provides the substantial equivalent of the specifically recited numerical value in the context in which the specifically recited numerical value is presented. For example, a statement that something has the numerical value of “about 10” is to be interpreted as: the set of statements:

    • in some embodiments the numerical value is 10;
    • in some embodiments the numerical value is in the range of 9.5 to 10.5;


      and if from the context the person of ordinary skill in the art would understand that values within a certain range are substantially equivalent to 10 because the values with the range would be understood to provide substantially the same result as the value 10 then “about 10” also includes:
    • in some embodiments the numerical value is in the range of C to D where C and D are respectively lower and upper endpoints of the range that encompasses all of those values that provide a substantial equivalent to the value 10


Specific examples of systems, methods and apparatus have been described herein for purposes of illustration. These are only examples. The technology provided herein can be applied to systems other than the example systems described above. Many alterations, modifications, additions, omissions, and permutations are possible within the practice of this invention. This invention includes variations on described embodiments that would be apparent to the skilled addressee, including variations obtained by: replacing features, elements and/or acts with equivalent features, elements and/or acts; mixing and matching of features, elements and/or acts from different embodiments; combining features, elements and/or acts from embodiments as described herein with features, elements and/or acts of other technology; and/or omitting combining features, elements and/or acts from described embodiments.


As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any other described embodiment(s) without departing from the scope of the present invention.


Any aspects described above in reference to apparatus may also apply to methods and vice versa.


Any recited method can be carried out in the order of events recited or in any other order which is logically possible. For example, while processes or blocks are presented in a given order, alternative examples may perform routines having steps, or employ systems having blocks, in a different order, and some processes or blocks may be deleted, moved, added, subdivided, combined, and/or modified to provide alternatives or subcombinations. Each of these processes or blocks may be implemented in a variety of different ways. Also, while processes or blocks are at times shown as being performed in series, these processes or blocks may instead be performed in parallel, simultaneously or at different times.


Various features are described herein as being present in “some embodiments”. Such features are not mandatory and may not be present in all embodiments. Embodiments of the invention may include zero, any one or any combination of two or more of such features. All possible combinations of such features are contemplated by this disclosure even where such features are shown in different drawings and/or described in different sections or paragraphs. This is limited only to the extent that certain ones of such features are incompatible with other ones of such features in the sense that it would be impossible for a person of ordinary skill in the art to construct a practical embodiment that combines such incompatible features. Consequently, the description that “some embodiments” possess feature A and “some embodiments” possess feature B should be interpreted as an express indication that the inventors also contemplate embodiments which combine features A and B (unless the description states otherwise or features A and B are fundamentally incompatible). This is the case even if features A and B are illustrated in different drawings and/or mentioned in different paragraphs, sections or sentences.


ADDITIONAL DESCRIPTION

Examples of wall panel mount assemblies, frames and clips thereof, and wall panel assemblies comprising the same, have been described. The following clauses are offered as further description.


(1) A frame for a wall panel, the frame comprising: a longitudinally-extending first portion shaped to abut and selectively connect to a periphery of the wall panel; and a longitudinally-extending second portion coupled to the first portion thereof, the second portion of the frame being shaped to abut and selectively connect to a rear of the wall panel.


(2) A frame according to any clause herein, wherein the first portion is channel-shaped or comprises a first channel.


(3) A frame according to any clause herein, wherein the second portion thereof is channel-shaped or comprises a second channel.


(4) A frame according to any clause herein, wherein the first portion has a first aperture extending therein.


(5) A frame according to any clause herein, wherein the first aperture is elongate in longitudinal and lateral profile.


(6) A frame according to any clause herein, wherein the second portion has a second aperture extending therein.


(7) A frame according to any clause herein, wherein the first aperture extends along or parallel to a first axis/plane and the second aperture extends along or parallel to a second axis/plane angled relative to the first axis/plane.


(8) A frame according to any clause herein, wherein the first aperture extends along or parallel to a first axis/plane and the second aperture extends along or parallel to a second axis/plane perpendicular to the first axis/plane.


(9) A frame according to any clause herein, wherein the first aperture extends along a first lateral direction and the second aperture extending along or parallel to a second lateral direction which is perpendicular to the first lateral direction.


(10) A frame according to any clause herein, wherein the periphery of the wall panel is C-shaped and the first portion is shaped to fit therewithin.


(11) A frame according to any clause herein, wherein the wall panel includes a central portion, a side portion coupled to and extending about the central portion thereof, and a rear portion coupled to and extending inwards from the side portion thereof.


(12) A frame according to any clause herein, wherein the first channel is shaped to fit within a recess formed by the central portion, the rear portion and the side portion of the wall panel.


(13) A frame according to any clause herein, wherein the first portion thereof is configured to connect to the side portion of the wall panel.


(14) A frame according to any clause herein, wherein the second portion thereof is configured to connect to the rear portion of the wall panel.


(15) In combination, a wall panel and a frame according to any clause herein.


(16) A frame for a wall panel, the frame comprising: a longitudinally-extending first portion shaped to abut a side or side portion of the wall panel; and a longitudinally-extending second portion coupled to the first portion thereof, the second portion of the frame being shaped to abut a rear or rear portion of the wall panel; wherein the frame is configured to selectively couple to the side or the rear of the wall panel.


(17) A frame according to any clause herein, wherein the first aperture in lateral-section extends substantially parallel to the rear, front and/or the central portion of the wall panel.


(18) A frame according to any clause herein, wherein the second aperture extends substantially parallel to the side or side portion of the wall panel.


(19) A frame according to any clause herein, wherein the wall panel couples to the first portion of the frame via at least a first fastener.


(20) A frame according to any clause herein, wherein the first fastener is configured to extend parallel to the rear, front and/or central portion of the wall panel.


(21) A frame according to any clause herein, wherein the wall panel couples to the second portion of the frame via at least a second fastener.


(22) A frame according to any clause herein, wherein the second fastener is configured to extend parallel to the side or side portion of the wall panel and/or perpendicular to the central portion of the wall panel.


(23) A frame assembly comprising a frame according to any clause herein and one or more fasteners via which the frame is selectively connectable to a wall panel.


(24) A frame according to any clause herein, wherein the first aperture comprises a fastener chase.


(25) A wall panel assembly comprising a frame according to any clause herein.


(26) A wall panel assembly comprising a wall panel according to any clause herein.


(27) A wall panel assembly comprising: a plurality of longitudinally-extending frames; a first wall panel configured to couple to a wall or wall substrate via a first said frame and at least a first fastener coupling together the first said frame and a side or side portion of the first wall panel; and a second wall panel configured to couple to the wall or wall substrate via a second said frame and a second fastener coupling together the second said frame and a rear or rear portion of the second wall panel.


(28) A frame for coupling wall panels to a wall or wall substrate, the frame being configured to couple either (i) a side-fastened said wall panel to the wall or wall substrate via at least a fastener coupling together the frame and a side or side portion of the side-fastened said wall panel or (ii) a rear-fastened said wall panel to the wall or wall substrate via at least a fastener coupling together the frame and a rear or rear portion of the rear-fastened said wall panel.


(29) A wall panel assembly comprising: a plurality of longitudinally-extending frames; a plurality of first wall panels each configured to couple to a wall or wall substrate via a respective first said frame and at least a first said fastener coupling together the first said frame and a side or side portion of the first wall panel thereof; and a plurality of second wall panels each configured to couple to the wall or wall substrate via a respective second said frame and at least a second said fastener coupling together the frame and a rear or rear portion of the second wall panel thereof.


(30) A wall panel assembly according to any clause herein, wherein each said first wall panel is a fastener-exposed said wall panel and wherein each said second wall panel is a fastener-hidden said wall panel.


(31) A wall panel assembly according to any clause herein, wherein for each said first wall panel the first fastener thereof is configured to be visible at least in part and wherein for each said second wall fastener the second fastener thereof is configured to be hidden therebehind.


(32) A wall panel assembly comprising: a first set of wall panels configured to couple to a wall or wall substrate via a first plurality of frames and exposed fasteners; and a second set of wall panels configured to couple to the wall or wall substrate via hidden fasteners and a second plurality of said frames.


(33) A wall panel assembly according to any clause herein, including a third set of wall panels configured to couple to the wall or wall substrate via both hidden and exposed fasteners and a third plurality of said frames


(34) A wall panel assembly comprising: a first set of wall panels configured to couple to a wall or wall substrate via a first plurality of frames and exposed fasteners; a second set of wall panels configured to couple to the wall or wall substrate via hidden fasteners and a second plurality of said frames; and a third set of wall panels configured to couple to the wall or wall substrate via both hidden and exposed fasteners and a third plurality of said frames


(35) A wall panel assembly according to any clause herein, wherein the frames which couple to the first set of wall panels have the same shape as the frames which couple to the second set of wall panels.


(36) A wall panel assembly according to any clause herein, including said frames.


(37) A wall panel assembly according to any clause herein, including said fasteners.


(38) A wall panel assembly according to any clause herein, wherein the first set of wall panels are shaped to receive fasteners through sides of peripheral portions thereof.


(39) A wall panel assembly according to any clause herein, wherein the second set of wall panels are shaped to receive fasteners through the rear of peripheral portions thereof.


(40) A wall panel mount system comprising a frame according to any clause herein.


(41) A wall panel mount system comprising a clip or bracket according to any clause herein.


(42) A frame for coupling to a fastener-exposed, fastener-hidden or combination fastener-exposed and fastener-hidden wall panel to a wall, the frame comprising: a first channel, wherein when the frame couples to the fastener-exposed wall panel or fastener-exposed portion of the combination fastener-exposed and fastener-hidden wall panel, the first channel is shaped to abut and receive one or more first fasteners extending through a side portion of the fastener-exposed wall panel or combination fastener-exposed and fastener-hidden wall panel; and a second channel coupled to the first channel, wherein when the frame couples to the fastener-hidden wall panel or fastener-hidden portion of the combination fastener-exposed and fastener-hidden wall panel, the second channel is shaped to receive a rear portion of the fastener-hidden wall panel or combination fastener-exposed and fastener-hidden wall panel and couple thereto via one or more second fasteners.


(43) A wall panel mount system comprising a pair of frames connectable to a pair of wall panels, the pair of frames being shaped to snap-fit together via a clip or bracket.


(44) A wall panel mount system according to any clause herein, wherein each said frame comprising an inner channel with angled surfaces shaped to facilitate insertion of the clip/bracket and/or an elongate planar member therein.


(45) A wall panel mount system according to any clause herein, wherein the first channel has a first said angled surface along which a first side or surface of the clip is slid towards the first channel and wherein the first channel has a second said surface opposite the first angled surface, the second said surface of the first channel abutting a second side or surface of the clip opposite the first side or surface of the clip and functioning to straight the clip out as the clip further enters the first channel.


(46) A wall panel mount system according to any clause herein, including said clip/bracket.


(47) A wall panel mount system according to any clause herein, including said fasteners.


(48) A wall panel mount system according to any clause herein, including said elongate planar member.


(49) A wall panel mount system according to any clause herein, wherein the inner channels of the frames are V-shaped in lateral profile.


(50) A wall panel mount system according to any clause herein, wherein each said inner channel includes a catch positioned along a distal end portion thereof.


(51) A wall panel mount system according to any clause herein, wherein for each said inner channel the distal end portion thereof is enlarged.


(52) A wall panel mount system according to any clause herein, wherein for each said inner channel the distal end portion thereof is tapered.


(53) A wall panel mount system according to any clause herein, wherein for each said inner channel the distal end portion thereof comprises angled surfaces.


(54) A wall panel mount system according to any clause herein, wherein each said inner channel includes a distal end portion which is wedge shaped and/or a triangular prism at least in part.


(55) A wall panel mount system according to any clause herein, wherein the clip/bracket includes at least one folded portion shaped to be received within the inner channel of one said frame.


(56) A wall panel mount system according to any clause herein, wherein the at least one folded portion is V-shaped is lateral profile.


(57) A wall panel mount system according to any clause herein, wherein the clip/bracket is couples to the inner channels via a pair of spaced-apart folded portions thereof.


(58) A wall panel mount system according to any clause herein, wherein the clip/bracket extends within the inner channels via a pair of spaced-apart folded portions thereof.


(59) A wall panel mount system according to any clause herein, wherein the clip/bracket is fixedly coupled to a first said frame and slidably couples to a second said frame.


(60) A wall panel mount system according to any clause herein, wherein the clip/bracket couples to a first said frame via at least one fastener and slidably couples to a second said frame.


(61) A clip/bracket for a wall panel mount system, the clip/bracket comprising a metal sheet that is folded over on itself.


(62) A clip/bracket according to any clause herein.


(63) A clip according to any clause herein, including a V-shaped bracket portion shaped to snap-fit couple to a frame.


(64) A clip according to any clause herein, including an L-shaped bracket portion shaped to abut a wall or wall substrate.


(65) A clip according to any clause herein, including a first subassembly with a ridge and including a second subassembly with a trough, with the ridge of the first subassembly being shaped to selectively nest with the trough of the second subassembly.


(66) A clip according to any clause herein, wherein the first subassembly includes a resilient portion shaped to snap-fit connect with a frame of the wall panel mount system.


(67) A clip according to any clause herein, wherein the ridge and trough so nested together are shaped to abut a wall and wherein one of the subassemblies includes an L-shaped bracket spaced-apart from the ridge and trough, with the L-shaped bracket being shaped to further abut the wall.


(68) A clip/bracket according to any clause herein, wherein the clip/bracket includes a protective membrane thereon.


(69) A clip/bracket according to any clause herein, wherein the protective membrane is made of a non-metal material.


(70) A clip/bracket according to any clause herein, wherein the protective membrane is made of an insulating material.


(71) A clip/bracket according to any clause herein, wherein the protective membrane is made of plastic.


(72) A wall panel mount system according to any clause herein, wherein the clip/bracket includes a protective membrane thereon which functions to isolate the frame and the clip.


(73) A clip/bracket according to any clause herein, wherein the clip/bracket includes: a first folded end portion shaped to be received within an inner channel of a first frame; and a second folded end portion shaped to be received within an inner channel of a second frame.


(74) A clip/bracket according to any clause herein, wherein the clip/bracket is shaped to fold about inner end and outer surfaces of a first frame and wherein the clip/bracket is shaped to slidably couple to a second frame.


(75) A clip/bracket according to any clause herein, including a ledge shaped to abut a wall or wall substrate.


(76) A clip/bracket according to any clause herein, wherein the ledge is formed via one or more bends.


(77) A clip/bracket according to any clause herein, wherein the ledge is L-shaped in lateral profile.


(78) A clip/bracket according to any clause herein, including an inverse U-shaped portion between the folded end portions thereof.


(79) A clip/bracket according to any clause herein, wherein the clip/bracket substantially extends along and/or covers outer surfaces of the inner channel of a first said frame.


(80) A clip/bracket according to any clause herein, wherein the clip/bracket is configured to snap-fit to the frames via the inner channels of the frames.


(81) A clip/bracket for a wall panel mount system, the clip/bracket being shaped to mount a pair of wall panels to a wall by snap-fit connecting together a pair of frames each connected to a respective said wall panel.


(82) A wall panel mount system comprising: first and second frames connectable to first and second wall panels, respectively, each said frame including an inner portion configured to be adjacent or near a wall or wall substrate; and a clip connectable to the wall or wall substrate, the clip slidably coupling to the first frame and enclosing the inner portion of the second frame.


(83) A wall panel mount system according to any clause herein, wherein the clip couples to the second frame at least in part by extending about an interior and exterior of an inner channel of the second frame.


(84) A wall panel mount system according to any clause herein, wherein the clip slidably couples to the inner portion of the first frame.


(85) A wall panel mount system according to any clause herein, wherein the clip snap-fit connects to the second frame.


(86) A method of coupling a pair of wall panels to a wall or wall substrate, the method comprising: coupling a pair of frames to respective ones of the wall panels; folding a metal sheet at least in part; fastening the metal sheet so folded to the wall or wall substrate; and coupling the frames to the wall or wall substrate via the metal sheet so folded.


(87) A method according to any clause herein, including within the forming step, folding the metal sheet so as to form a clip.


(88) A method according to any clause herein, including within the coupling the frames to the wall or wall substrate step, shaping the metal sheet so folded to snap-fit couple to a first said frame and slidably couple to a second said frame.


(89) A frame for coupling a wall panel to a wall or wall substrate, wherein the frame has an inner side and an outer side spaced-apart from the inner side thereof, and wherein the inner side of the frame is shaped to inhibit pooling of fluid thereon.


(90) A frame according to any clause herein, wherein the frame has exterior surfaces along the inner side thereof, with the exterior surfaces being shaped to angle fluid away therefrom and outwards from the frame.


(91) A frame according to any clause herein, wherein the frame has an inner end and an outer end spaced-apart from the inner end thereof, with the inner and outer sides of the frame extending between the inner and outer ends of the frame, and wherein the exterior surfaces along the inner side of the frame extend from the inner end to the outer end of the frame.


(92) A frame according to any clause herein, wherein the exterior surfaces along the inner side of the frame comprise a plurality of L-shapes in lateral profile.


(93) A frame according to any clause herein, wherein the frame has an inner end and an outer end spaced-apart from the inner end thereof, with the inner and outer sides of the frame extending between the inner and outer ends of the frame, and wherein the frame along the inner side thereof, comprises a first or inner L-shaped bracket portion facing the inner end thereof and a second or outer L-shaped bracket portion facing the outer end thereof.


(94) A frame according to any clause herein, wherein the frame includes a third or intermediate L-shaped bracket portion facing one of the inner and outer ends thereof, the third or intermediate L-shaped bracket portion extending between and coupling together the first or inner L-shaped bracket portion and the second or outer L-shaped bracket portion.


(95) A frame according to any clause herein, wherein the third or intermediate L-shaped bracket portion is laterally outwardly positioned relative to the first or inner L-shaped bracket portion and the second or outer L-shaped bracket portion.


(96) A frame according to any clause herein, wherein the frame has an inner end and an outer end spaced-apart from the inner end thereof, with the inner and outer sides of the frame extending between the inner and outer ends of the frame, and wherein the frame along the inner side thereof, comprises a first one or more steps which direct fluid thereon to the inner end thereof and a second one or more steps which direct fluid thereon to the outer end thereof.


(97) A frame according to any clause herein, wherein the frame has two or more angled outer surfaces shaped for promoting removal of fluid therefrom and/or promoting rainscreen control thereof.


(98) A frame for a wall panel mount system, the frame comprising a series of longitudinally-extending channels and exterior surfaces thereof shaped to angle fluid away therefrom and/or outwards from the frame.


(99) A frame according to any clause herein, wherein the frame has sloped surfaces configured to divert water and/or inhibit pooling of water.


(100) A frame according to any clause herein, wherein the frame comprises three said channels.


(101) A frame according to any clause herein, wherein the frame has an inner side and an outer side spaced-apart from the inner side thereof, and wherein each said channel faces said outer side of the frame.


(102) A frame according to any clause herein, wherein the channels form a plurality of C-shapes in lateral section each facing the same direction.


(103) A frame according to any clause herein, including an inner said channel, an outer said channel and a middle said channel extending between and laterally outwardly positioned from the inner said channel and the outer said channel.


(104) A frame according to any clause herein, including an inner said channel, an outer said channel and a middle said channel extending between and inhibiting fluid communication between the inner said channel and the outer said channel.


(105) A frame according to any clause herein, wherein the frame has a longitudinal axis, with surfaces between an inner end and the longitudinal axis thereof being shaped to promote movement of fluid towards the inner end thereof, and with surfaces between an outer end and the longitudinal axis thereof being shaped to promote movement of fluid towards the outer ends thereof.


(106) A frame according to any clause herein, including a laterally-extending flange positioned between the inner end and the outer end thereof.


(107) A frame according to any clause herein, wherein the flange is shaped to inhibit fluid from moving from the inner end to the outer end of the frame and vice versa.


(108) A frame according to any clause herein, wherein the frame is shaped to promote movement of fluid to either side of the flange.


(109) A frame for coupling a wall panel to a wall or wall substrate, with surfaces along an inner side thereof between an inner end and a central portion thereof being shaped to promote movement of fluid towards the inner end thereof, and with surfaces along the inner side thereof between an outer end and the central portion thereof being shaped to promote movement of fluid towards the outer end thereof.


(110) A frame according to any clause herein, wherein the central portion thereof comprises a laterally-extending flange positioned between the inner end and the outer end thereof.


(111) A wall panel assembly comprising: a wall panel with a frame member coupled to a peripheral side thereof, wherein the wall panel has an aperture extending through an exterior thereof and wherein the frame member has an aperture in fluid communication with an inner side of the wall panel and the aperture of the wall panel, with the aperture of the wall panel being longitudinally spaced from the aperture of the frame.


(112) A wall panel assembly comprising: a wall panel with one or more apertures extending through a bottom side portion thereof; and a frame coupled to the bottom side portion of the wall panel, the frame having one or more apertures in fluid communication with an inner side and the one or more apertures of the wall panel.


(113) A wall panel assembly according to any clause herein, wherein the aperture of the wall panel is a weep hole.


(114) A wall panel assembly according to any clause herein, wherein the aperture of the frame is an inner-facing aperture.


(115) A wall panel assembly according to any clause herein, wherein the aperture of the wall panel and the aperture of the frame so offset, inhibit wind driven rain from entering through the wall panel assembly.


(116) A wall panel assembly according to any clause herein, wherein the aperture of the wall panel and the aperture of the frame so offset, inhibit wind driven rain from contacting/or and spraying a wall and/or wall substrate.


(117) A wall panel assembly according to any clause herein, wherein the aperture of the wall panel and the aperture of the frame are configured/positioned to promote pressure equalization.


(118) A wall panel assembly according to any clause herein, wherein the aperture of the wall panel and the aperture of the frame are in fluid communication via a longitudinally-extending channel of the frame.


(119) A wall panel assembly according to any clause herein, wherein the longitudinally-extending channel of the frame is a fastener chase.


(120) A wall panel assembly according to any clause herein, wherein the frame is configured to couple the wall panel to a wall or wall substrate and wherein the inner side of the wall panel is configured to face the wall or wall substrate.


(121) A wall panel assembly according to any clause herein, wherein the one or more apertures of the wall panel are longitudinally spaced from the one or more apertures of the frame.


(122) A wall panel assembly according to any clause herein, wherein the one or more apertures of the wall panel are laterally offset from and align longitudinally with the one or more apertures of the frame.


(123) A wall panel assembly according to any clause herein, including one or more fasteners selectively threadably couple with the longitudinally-extending channel of the frame, with the frame and the bottom side portion of the wall panel coupling together via the one or more fasteners.


(124) A wall panel assembly according to any clause herein, wherein each said aperture extends about an axis substantially parallel to a front face of the wall panel.


(125) A wall panel assembly according to any clause herein, wherein the aperture of the wall panel is centrally positioned along a side thereof.


(126) A wall panel assembly according to any clause herein, wherein the wall panel includes left and right side portions between which extends the bottom side portion thereof, with the wall panel having a first said aperture near or adjacent the left side portion thereof and a second said aperture near or adjacent the right side portion thereof.


(127) A wall panel assembly according to any clause herein, wherein the wall panel assembly and/or components thereof are configured to function as a rainscreen.


(128) A wall panel assembly according to any clause herein, wherein the wall panel assembly comprises a rainscreen said wall panel assembly.


(129) A wall panel assembly comprising: a wall panel having one or more apertures extending through a bottom side portion thereof; and a frame configured to couple the wall panel to a wall or wall substrate, the frame including a channel in fluid communication with the one or more apertures of the wall panel, the channel including a pair of side portions with longitudinally-extending ridges and grooves thereon, including a closed end portion extending between said side portions thereof and having one or more apertures extending through said closed end portion thereof.


(130) A wall panel assembly according to any clause herein, including one or more fasteners selectively engageable with the ridges and grooves of the frame, with the frame and the bottom side portion of the wall panel coupling together via the one or more fasteners.


(131) A wall panel assembly comprising: a plurality of longitudinally-extending frames; and a wall panel configured to couple to a wall or wall substrate via i) at least a first said frame and at least a first fastener coupling together the first said frame and a side or side portion of the wall panel and ii) at least a second said frame and a second fastener coupling together the second said frame and a rear or rear portion of the wall panel.


(132) A wall panel assembly according to any clause herein, wherein each said frame is substantially the same in shape.


(133) A frame for a wall panel assembly according to any clause herein.


(134) In combination, one or more wall panels and a wall panel assembly according to any clause herein.


(135) A kit comprising: a plurality of frames according to any clause herein; and a plurality of clips/brackets according to any clause herein.


(136) A kit comprising: a plurality of frames and wall panels each according to any clause herein; and a plurality of clips via which the frames couple the wall panels to a wall or wall substrate.


(137) A frame for coupling a wall panel to a wall or wall substrate via a clip, the frame having two modes for connecting to either a fastener-exposed said wall panel or a fastener-concealed said wall panel with the same frame profile.


(138) A method of installing a wall panel assembly on a wall or wall substrate, the method comprising: coupling a first plurality of frames each according to claim 9, to rear portions of a first set of wall panels having peripheries that are C-shaped in lateral section; coupling a second plurality of frames each according to any clause herein, to side portions of a second set of wall panels having peripheries that are L-shaped in lateral section; and mounting the wall panels to the wall via a plurality of clips which selectively couple to the frames so coupled thereto.


(139) A method according to any clause herein, including within the mounting step: mounting the first set of wall panels on a lower portion of the wall; and mounting the second set of wall panels on an upper portion of the wall.


(140) A method according to any clause herein, including within the step of coupling the first plurality of frames to the first set of wall panels: providing the frames with longitudinally-extending first portions shaped to snugly fit within respective C-shaped peripheries of the first set of wall panels.


(141) A method according to any clause herein, including within the step of coupling the first plurality of frames to the first set of wall panels: providing the frames with longitudinally-extending channels shaped to snugly receive therewithin at least in part respective said rear portions of the first set of wall panels.


(142) A frame for coupling a wall panel to a wall or wall substrate via a clip, the frame including one or more weep holes and a drainage gutter cavity in fluid communication with the one or more weep holes, and the wall panel having one or more weep holes offset from the one or more weep holes and in fluid communication with the drainage gutter cavity.


(143) A wall panel assembly according to any clause herein, wherein said drainage gutter cavity and said weep holes align longitudinally.


(144) A wall panel assembly comprising the frame, the wall panel and the clip of any clause herein.


(145) A frame for coupling a wall panel to a wall or wall substrate via a clip, the frame having two or more angled outer surfaces shaped for promoting removal of fluid therefrom and/or promoting rainscreen control thereof.


(146) A wall panel mount system comprising: first and second frames connectable to first and second wall panels, respectively; and a clip connectable to a wall or wall substrate, the clip including a clip snap interface or first male portion which snap-fit connects to the first frame and the clip including a clip slide function interface or second male portion which slidably couples to and/or extends within a female portion of the second frame.


(147) A wall panel mount system according to any clause herein, wherein each said frame includes a female portion configured to receive a respective said male portion of the clip.


(148) A wall panel mount system according to any clause herein, wherein the first male portion of the clip is resilient and/or inwardly deformable.


(149) A wall panel mount system according to any clause herein, wherein the first male portion of the clip is V-shaped is lateral profile.


(150) A wall panel mount system according to any clause herein, wherein the male portions of the clip are formed by moving the clip from an at least partially planar or unfolded position to a folded position.


(151) A method of coupling a pair of wall panels to a wall or wall substrate, the method comprising: coupling first and second frames to respective ones of the wall panels; fastening the clip of any clause herein to the wall or wall substrate; and inserting the male portions of the clip into female portions of the frames so as to snap-fit connect to the first frame and slidably couple to the second frame.


(152) A wall panel mount system comprising: a pair of frames connectable to a pair of wall panels; and a clip connectable to a wall or wall substrate, the clip being configured to snap-fit connect to a first said frame via a folded portion thereof and the clip being configured to slidably connecting to a second said frame.


(153) A wall panel mount system comprising: a pair of frames connectable to a pair of wall panels; and a clip connectable to a wall or wall substrate, the clip snap-fit connecting to a first said frame and slidably connecting to a second said frame, with each said frame including an inner channel with one or more angled surfaces shaped to facilitate insertion of the clip therein.


(154) A wall panel mount system according to any clause herein, wherein for each said frame the one or more angled surfaces thereof are angled relative to the wall panels and/or the wall or wall substrate.


(155) A wall panel mount system according to any clause herein, wherein the inner channels of the frames are V-shaped in lateral profile.


(156) A wall panel mount system according to any clause herein, wherein each said inner channel includes a catch via which the clip snap-fit connects with one of said frames.


(157) A wall panel mount system according to any clause herein, wherein each said inner channel includes a distal end portion shaped to facilitate insertion of the clip therein and inhibit dislodgement thereof thereafter.


(158) A wall panel mount system according to any clause herein, wherein the clip couples to and/or extends within the inner channels via a pair of spaced-apart folded portions thereof.


(159) A wall panel mount system according to any clause herein, wherein the clip is made of metal and a protective membrane extending thereabout, with the protective membrane functioning to isolate the metal of the clip from the frames.


(160) A method of coupling a wall panel to a wall or wall substrate, the method comprising: drilling an aperture through a side portion of the wall panel; forming a recessed region about the aperture via a protrusion pressed into the aperture; and threadably coupling the side portion of the wall panel to a frame via a fastener inserted into the aperture; operatively connecting the wall panel the wall or wall substrate via the frame.


(161) A method according to any clause herein, including within the operatively connecting step, operatively connecting the frame to the wall or wall substrate via a clip or bracket.


(162) A method according to any clause herein, including within the forming step, forming the recessed region such that a fastener head of the fastener so coupled to the frame is flush with the side portion of the wall panel.


(163) A method according to any clause herein, including shaping said protrusion to be frustoconical at least in part.


(164) A method according to any clause herein, wherein the recessed region is coaxial with the aperture.


(165) A method according to any clause herein, wherein the recessed region is laterally outwardly facing.


(166) A method according to any clause herein, wherein the recessed region comprises a dimpled portion of the wall panel.


(167) A method according to any clause herein, including using a punch tool to form the recessed region about the aperture.


(168) A method of coupling a wall panel to a wall or wall substrate, the method comprising: drilling an aperture through a side portion of the wall panel; pressing a protrusion into the aperture so as form a countersunk said aperture; and threadably coupling the side portion of the wall panel to a frame via a fastener inserted into the aperture so countersunk; coupling the wall panel to the wall or wall substrate via the frame.


(169) A method of coupling a wall panel to a wall or wall substrate, the method comprising: drilling an aperture through a side portion of the wall panel; countersinking the aperture via a protrusion pressed into the aperture; and threadably coupling the side portion of the wall panel to a frame via a fastener inserted into the aperture so countersunk; coupling the wall panel to the wall or wall substrate via the frame.


(170) A method according to any clause herein, wherein the wall panel includes an outer layer or coating thereon and the method includes: inhibiting damage to the outer layer or coating of the wall panel when countersinking the aperture and/or forming the recessed region.


(171) A method according to any clause herein, wherein the wall panel is made of a first metal with a non-metal coating thereon and the fastener is made of a second metal which is different than the first metal, and wherein the method includes: promoting metal isolation between the wall panel and the fastener by countersinking the aperture and/or forming the recessed region so as to and/or in a manner which inhibits damage to said non-metal coating.


(172) A wall panel mount system comprising: a wall panel having one or more apertures extending through one or more side portions thereof, with each said aperture being countersunk via a protrusion pressed therein; and a frame threadably connectable to the wall panel via one or more fasteners configured to extend through respective said one or more apertures of the side portions of the wall panel.


(173) A wall panel mount system according to any clause herein, wherein one or more fasteners so threadably coupled in place are configured to remain flush with the one or more side portions of the wall panel.


(174) A wall panel mount system according to any clause herein, wherein each said fastener includes a fastener head shaped to be flush with a respective said side portion of the wall panel when threadably coupled in place.


(175) A wall panel mount system according to any clause herein, wherein the wall panel is made of a first metal with a non-metal coating thereon and wherein the one or more fasteners are made of a second metal which is different from the first metal.


(176) A wall panel mount system according to any clause herein, wherein the protrusion is frustoconical at least in part.


(177) A wall panel mount system according to any clause herein, wherein the protrusion is a bit and/or part of a punch tool.


(178) A wall panel mount system comprising: a wall panel including one or more side portions with one or more outwardly-facing dimpled or recessed regions extending therein and with each said dimpled or recessed region having an aperture extending therethrough; and a frame threadably connectable to the wall panel via at least one fastener configured to extend through a respective said aperture of the dimpled or recessed regions of the side portions of the wall panel.


(179) A wall panel mount system according to any clause herein, wherein each said dimpled or recessed region is formed via a press.


(180) A wall panel mount system according to any clause herein, wherein each said dimpled or recessed region is formed via a punch tool or machine.


(181) A wall panel mount system according to any clause herein, wherein each said dimpled or recessed region is formed via a protrusion which is frustoconical in shape.


(182) A wall panel mount system according to any clause herein, including a clip via which the frame is connectable to a wall or wall substrate.


(183) A wall panel assembly comprising the first and second wall panels together with the wall panel mount system of any other clause herein.


(184) Apparatus including any new and inventive feature, combination of features, or sub-combination of features as described herein.


(185) Methods including any new and inventive steps, acts, combination of steps and/or acts or sub-combination of steps and/or acts as described herein.


It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions, omissions, and sub-combinations as may reasonably be inferred. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

Claims
  • 1. A wall panel mount system comprising: first and second frames connectable to first and second wall panels, respectively; anda clip connectable to a wall or wall substrate, the clip including a first male portion which snap-fit connects to the first frame and a second male portion which slidably couples to the second frame.
  • 2. A wall panel mount system according to claim 1, wherein each said frame includes a female portion configured to receive a respective said male portion of the clip.
  • 3. A wall panel mount system according to claim 1, wherein the first male portion of the clip is resilient and/or inwardly deformable.
  • 4. A wall panel mount system according to claim 1, wherein the first male portion of the clip is V-shaped is lateral profile.
  • 5. A wall panel mount system according to claim 1, wherein the male portions of the clip are formed by moving the clip from an at least partially planar or unfolded position to a folded position.
  • 6. A wall panel mount system according to claim 1, wherein the clip is made of metal sheet.
  • 7. A method of coupling a pair of wall panels to a wall or wall substrate, the method comprising: coupling first and second frames to respective ones of the wall panels;fastening the clip of claim 1 to the wall or wall substrate; andinserting the male portions of the clip into female portions of the frames so as to snap-fit connect to the first frame and slidably couple to the second frame.
  • 8. A wall panel mount system comprising: a pair of frames connectable to a pair of wall panels; anda clip connectable to a wall or wall substrate, the clip being configured to snap-fit connect to a first said frame via a folded portion thereof and the clip being configured to slidably connecting to a second said frame.
  • 9. A wall panel mount system comprising: a pair of frames connectable to a pair of wall panels; anda clip connectable to a wall or wall substrate, the clip snap-fit connecting to a first said frame and slidably connecting to a second said frame, with each said frame including an inner channel with one or more angled surfaces shaped to facilitate insertion of the clip therein.
  • 10. A wall panel mount system according to claim 9, wherein for each said frame the one or more angled surfaces thereof are angled relative to the wall panels and/or the wall or wall substrate.
  • 11. A wall panel mount system according to claim 9, wherein the first channel has a first said angled surface along which a first side of the clip is slid towards the first channel and wherein the first channel has a second said surface opposite the first angled surface, the second said surface of the first channel abutting a second surface of the clip opposite the first surface of the clip and functioning to straight the clip out as the clip further enters the first channel.
  • 12. A wall panel mount system according to claim 9, wherein the inner channels of the frames are V-shaped in lateral profile.
  • 13. A wall panel mount system according to claim 9, wherein each said inner channel includes a catch via which the clip snap-fit connects with one of said frames.
  • 14. A wall panel mount system according to claim 9, wherein each said inner channel includes a distal end portion which is enlarged.
  • 15. A wall panel mount system according to claim 9, wherein each said inner channel includes a distal end portion and wherein one or more of: the distal end portion of the inner channel has one or more angled surfaces; and the distal end portion of the inner channel is shaped to facilitate insertion of the clip therein and inhibit dislodgement thereof thereafter.
  • 16. A wall panel mount system according to claim 9, wherein each said inner channel includes a distal end portion which is one or more of tapered, wedge shaped and a triangular prism at least in part.
  • 17. A wall panel mount system according to claim 9, wherein the clip couples to and/or extends within the inner channels via a pair of spaced-apart folded portions thereof.
  • 18. A wall panel mount system according to claim 9, wherein the clip is made of metal and a protective membrane extending thereabout, with the protective membrane functioning to isolate the metal of the clip from the frames.
  • 19. A kit comprising a plurality of frames and a plurality of clips via which the frames couple wall panels to a wall or wall substrate, the frames and the clips being according to claim 9.
  • 20. A wall panel assembly comprising the first and second wall panels together with the wall panel mount system as claimed in claim 9.
Provisional Applications (1)
Number Date Country
63597302 Nov 2023 US