FIELD OF INVENTION
The present invention relates generally to the art of exterior walls of buildings, and more specifically to a wall panel, a method of assembly thereof, and a wall panel system, and a method of installation thereof.
BACKGROUND
Exterior wall systems such as curtain wall systems are used in the construction industry as an exterior building cover. These wall systems are non-loadbearing and are attached to horizontal and vertical loadbearing members that are part of the building structure. Thus, any loads inflicted on these wall systems, including its own dead load and live loads, are transferred to other members of the building structure. The design of these wall systems also impacts how the systems are constructed, consequently influencing the speed and cost of completion.
Curtain walls can generally be classified as stick-built or unitized systems. Stick systems are comprised of wall frame verticals and horizontals, or mullions, and glass or opaque panels. These parts are installed and connected piece by piece on a project site typically with fasteners, gaskets, and/or sealant. Unitized systems, on the other hand, are comprised of panels that are mostly fabricated, assembled, and glazed in the factory. These pre-assembled panels are then installed on the building by connecting the panels to the building structure. The unitized system is intended to be an improvement over traditional stick systems by allowing for quicker installation.
Although conventional unitized curtain wall systems provide some advantages over the conventional stick systems, the offsite fabrication and assembly of panels and later installation to the building structure are difficult. Because conventional curtain wall systems are non-loadbearing, panels must be anchored to the building structure to transfer any loads imposed on the panels back to the building structure. Therefore, the anchors and building members must be designed for the additional dead loads and live loads from the panels, creating costly anchor and building member designs.
Additionally, panels must be fabricated with close tolerances to allow for the alignment of panels during installation and to create an adequate seal between panels once installed. Because the panels must be anchored to the building structure while maintaining a sufficient alignment and seal between panels, construction of the conventional curtain wall system can be complicated, problematic, time consuming, and costly.
On the other hand, non-curtain wall systems, including conventional loadbearing wall systems, require installation of some, if not all, exterior components of the wall on the project site. These exterior components include weather barriers, insulation, and cladding. Because many components of the loadbearing wall must be installed in the field, the construction of these wall systems, like the curtain wall system, can be complicated and time consuming, resulting in more costly construction.
SUMMARY
In one aspect, a wall panel is provided that can be prefabricated and pre-assembled, and can be easily and quickly installed in the field. The wall panel includes an exterior infill component, an interior structural component, and a frame. The frame includes a first jamb member, a second jamb member, a head member, and a sill member. A wall system is provided comprising a plurality of wall panels. A method of installing the wall panel system and a method of assembling the wall panel are also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary, as well as the following detailed description will be better understood when read in conjunction with the appended drawings. For the purpose of illustration, there is shown in the drawings different embodiments. It should be understood, however, that the teachings are not limited to the precise wall panel and wall panel system arrangement shown.
FIG. 1 is a front, right perspective view of a wall panel.
FIG. 2 is a front, right perspective view of the wall panel shown exploded to show the components of the wall panel.
FIG. 3 is a front view of a frame.
FIG. 4A is a first embodiment of the cross-section view of section A-A from FIG. 3.
FIG. 4B is a second embodiment of the cross-section view of section A-A from FIG. 3.
FIG. 5A is a first embodiment of the cross-section view of section B-B from FIG. 3.
FIG. 5B is a second embodiment of the cross-section view of section B-B from FIG. 3.
FIG. 6A is a plan view of a first embodiment of a joined first jamb member and a second jamb member.
FIG. 6B is a plan view of a second embodiment of a joined first jamb member and a second jamb member.
FIG. 7A is a first embodiment of the cross-section view of section C-C from FIG. 3.
FIG. 7B is a second embodiment of the cross-section view of section C-C from FIG. 3.
FIG. 7C is a third embodiment of the cross-section view of section C-C from FIG. 3.
FIG. 8A is a first embodiment of the cross-section view of section D-D from FIG. 3.
FIG. 8B is a second embodiment of the cross-section view of section D-D from FIG. 3.
FIG. 8C is a third embodiment of the cross-section view of section D-D from FIG. 3.
FIG. 9A is an elevation view of a first embodiment of a joined head member and a sill member.
FIG. 9B is an elevation view of a second embodiment of a joined head member and a sill member.
FIG. 9C is an elevation view of a third embodiment of a joined head member and a sill member.
FIG. 10 is a front view of a first corner, a second corner, a third corner, and a fourth corner.
FIG. 11 is a front, left perspective view of an exemplary notched first jamb angle and a head angle.
FIG. 12 is a flow chart of a method of assembling the wall panel.
FIG. 13 is a front, right perspective view of a wall panel system, shown partially installed.
FIG. 14A is a front, left perspective view of a first embodiment of the top left portion of a first wall panel.
FIG. 14B is a front, left perspective view of a second embodiment of the first wall panel.
FIG. 14C is a front, left perspective view of a third embodiment of the first wall panel.
FIG. 15A is a front, left perspective view of a first embodiment of the top portion of a second wall panel installed with the first wall panel of FIG. 14A.
FIG. 15B is a front, left perspective view of a second embodiment of the second wall panel installed with the first wall panel of FIG. 14B.
FIG. 15C is a front, left perspective view of a third embodiment of the second wall panel installed with the first wall panel of FIG. 14C.
FIG. 16A is a front, left perspective view of a first embodiment of the bottom portion of a third wall panel installed with the first wall panel and the second wall panel of FIG. 15A.
FIG. 16B is a front, left perspective view of a second embodiment of the third wall panel installed with the first wall panel and the second wall panel of FIG. 15B.
FIG. 16C is a front, left perspective view of a third embodiment of the third wall panel installed with the first wall panel and the second wall panel of FIG. 15C.
FIG. 17A is a front, left perspective view of a first embodiment of the bottom portion of a fourth wall panel installed with the first wall panel, the second wall panel, and the third wall panel of FIG. 16A.
FIG. 17B is a front, left perspective view of a second embodiment of the fourth wall panel installed with the first wall panel, the second wall panel, and the third wall panel of FIG. 16B.
FIG. 17C is a front, left perspective view of a third embodiment of the fourth wall panel installed with the first wall panel, the second wall panel, and the third wall panel of FIG. 16C.
FIG. 18A is a plan view of a first embodiment of adjacent wall panels of the wall panel system.
FIG. 18B is a plan view of a second embodiment of adjacent wall panels of the wall panel system.
FIG. 19A is a cross-section view of a first embodiment of stacked wall panels of the wall panel system.
FIG. 19B is a cross-section view of a second embodiment of stacked wall panels of the wall panel system.
FIG. 19C is a cross-section view of a third embodiment of stacked wall panels of the wall panel system.
FIG. 20 is a front, left perspective view of the intersection of the wall panel system showing the gaskets and the silicone tape.
FIG. 21 is a flow chart of a method of installing the wall panel system.
DETAILED DESCRIPTION
A wall panel is provided that can be loadbearing, can be pre-assembled in a factory, and can be quickly and efficiently installed in the field. The wall panel includes an exterior infill component, an interior structural component, and a frame. The frame includes a first jamb member, a second jamb member, a head member, and a sill member. The frame allows a wall panel to connect to up to four other wall panels, one on each side of the frame. A plurality of wall panels fit together like a puzzle via their frames to form an exterior wall of a building.
FIG. 1 is a front, right perspective view of a wall panel 100. The wall panel 100 can be prefabricated, pre-assembled and shipped to the field. In the field, these wall panels connect together to create a wall panel system for exterior building enclosures.
FIG. 2 is a front, right perspective view of the wall panel 100 shown exploded to show the components of the wall panel 100. As shown in FIG. 2, a wall panel 100 includes an exterior infill component 200, an interior structural component 220, and a frame 210. The frame 210 connects to the interior structural component 220, and the exterior infill component 200 also connects to the interior structural component 220 to create a wall panel 100. When the wall panel 100 is assembled, the frame protrudes out from the wall panel 100. The frame 210 allows the wall panel 100 to connect to the frame 210 of adjacent wall panels 100.
FIG. 2 shows the components of the exterior infill component 200. As shown in FIG. 2, the exterior infill component 200 may include a cladding component 202, a plurality of furring strips 204, and an insulation component 206. The exterior infill component 200 may include only some of these components or include additional components. The cladding component 202 may be either fiber cement cladding or metal panel cladding. However, any building code approved cladding material can be used. The cladding component 202 is the exterior of the wall panel 100. A cladding component 202 material may be chosen to achieve the desired aesthetics of the building. The furring strips 204 may be made from galvanized steel channels. The furring strips 204 connect the cladding component 202 to other wall panel 100 components. The insulation component 206 may be any building code approved exterior continuous insulation. The insulation component 206 insulates the interior of a building from its surrounding environment. The components of the exterior infill component 200 are connected together via fasteners or other attachment methods such as adhesive or clips.
FIG. 2 also illustrates the components of the interior structural component 220. As shown in FIG. 2, the interior structural component 220 may include a weather barrier 222, a structural sheathing component 224, and a structural frame 226. The interior structural component 220 may include only some of these components or include additional components. The weather barrier 222 protects the interior components and the structure itself from moisture damage and prevents the free passage of air. The structural frame 226 may comprise a bottom plate 228, a top plate 227, and vertical studs 229. The structural sheathing component 224 and the structural frame 226 allow the wall panel 100 to be structural or load-bearing. The components of the interior structural component 220 are connected together via fasteners or other attachment methods such as adhesive or clips.
FIG. 3 is a front view of the frame 210. The frame 210 includes a first jamb member 310, a second jamb member 312, a head member 314, and a sill member 316. FIG. 3 illustrates the right side member of the frame 210 comprising the first jamb member 310, the left side of the frame 210 comprising the second jamb member 312, the top member of the frame 210 comprising the head member 314, and the bottom member of the frame 210 comprising the sill member 316. However, alternative arrangements and designs are possible.
FIG. 4A is a first embodiment of the cross-section view of section A-A from FIG. 3. FIG. 4A shows a jamb extension 1310 as the first jamb member 310. FIG. 4B is a second embodiment of the cross-section view of section A-A from FIG. 3. FIG. 4B shows a first jamb angle 2310 as the first jamb member 310. FIGS. 4A and 4B depict exemplary designs of the first jamb member 310. However, other designs may be utilized for the first jamb member 310.
FIG. 5A is a first embodiment of the cross-section view of section B-B from FIG. 3. FIG. 5A shows a jamb receiver 1312 as the second jamb member 312. FIG. 5B is a second embodiment of the cross-section view of section B-B from FIG. 3. FIG. 5B shows a second jamb angle 2312 as the second jamb member 312. FIGS. 5A and 5B depict exemplary designs of the second jamb member 312. However, other designs may be utilized for the second jamb member 312.
The first jamb angle 2310 and the second jamb angle 2312 may each include at least one race-way. When the wall panels 100 are installed on the project site, these race-ways are used to guide and hold seals or gaskets 502, as shown in FIG. 6B and discussed in more detail herein.
FIG. 6A is a plan view of a first embodiment of a joined first jamb member 310 and a second jamb member 312. FIG. 6B is a plan view of a second embodiment of a joined first jamb member 310 and a second jamb member 312. As shown in FIGS. 6A and 6B, the designs of the first jamb member 310 and the second jamb member 312 correlate to allow the first jamb member 310 of a wall panel 100 to mate with the second jamb member 312 of an adjacent second wall panel 100. FIGS. 6A and 6B show two different exemplary embodiments of a first jamb 310 mating with a second jamb 312. FIG. 6A shows an exemplary mating of a jamb extension 1310 and jamb receiver 1312. FIG. 6B shows an exemplary mating of a first jamb angle 2310 and second jamb angle 2312. As shown in FIG. 6B, a seal or gasket 502 may be compressed between the first jamb angle 2310 and the second jamb angle 2312 to seal the joint.
FIG. 7A is a first embodiment of the cross-section view of section C-C from FIG. 3. FIG. 7A shows a head extension 1314 as the head member 314. FIG. 7B is a second embodiment of the cross-section view of section C-C from FIG. 3. FIG. 7B shows a head angle 2314 as the head member 314. FIG. 7C is a third embodiment of the cross-section view of section C-C from FIG. 3. FIG. 7C shows a T-shaped head extension 3314 as the head member 314. The T-shaped head extension 3314 may be used in conjunction with the head angle 2314. FIGS. 7A, 7B, and 7C depict exemplary designs of the head member 314. However, other designs may be utilized for the head member 314.
FIG. 8A is a first embodiment of the cross-section view of section D-D from FIG. 3. FIG. 8A shows a sill receiver 1316 as the sill member 316. FIG. 8B is a second embodiment of the cross-section view of section D-D from FIG. 3. FIG. 8B shows a sill angle 2316 as the sill member 316. FIG. 8C is a third embodiment of the cross-section view of section D-D from FIG. 3. FIG. 8C shows a brake-formed sill receiver 3316 as the sill member 316. FIGS. 8A, 8B, and 8C depict exemplary designs of the sill member 316. However, other designs may be utilized for the sill member 316.
FIG. 9A is an elevation view of a first embodiment of a joined head member 314 and a sill member 316. FIG. 9B is an elevation view of a second embodiment of a joined head member 314 and a sill member 316. FIG. 9C is an elevation view of a third embodiment of a joined head member 314 and a sill member 316. As shown in FIGS. 9A, 9B, and 9C, the designs of the head member 314 and the sill member 316 correlate to allow the head member 314 of a first wall panel 100 to mate with the sill member 316 of a stacked second wall panel 100. FIG. 9A shows an exemplary joint of a head extension 1314 and a sill receiver 1316. FIG. 9B shows an exemplary joint of a head angle 2314 and a sill angle 2316. FIG. 9C shows an exemplary joint of a T-shaped head extension 3314 and a brake-formed sill receiver 3316. As shown in FIG. 9C, the head angle 2314 and the T-shaped head extension 3314 may be used in combination with the brake-formed sill receiver 3316. In this embodiment, the T-shaped head extension 3314 may run across the entire length of the top of the wall panel 100 or may run a partial length of the top of the wall panel 100. The T-shaped head extension 3314 may be attached to the head angle 2314 in the factory or on the project site. The head angle 2314, the sill angle 2316, the T-shaped head extension 3314, and the brake-formed sill receiver 3316 may each include at least one race-way. When the wall panels 100 are installed on the project site, these race-ways may be used to guide and hold gaskets 504, as shown in FIGS. 9B and 9C. Further details of the seals or gaskets 504 are discussed below.
FIG. 10 is a front view of a first corner 410, a second corner 420, a third corner 430, and a fourth corner 440. The frame 210 may include a first corner 410, a second corner 420, a third corner 430, and a fourth corner 440. Exemplary details of the corners 410, 420, 430, 440 are illustrated in FIG. 10. The corners 410, 420, 430, 440 correspond to the frame 210 depicted in FIG. 3. More specifically, each corner 410, 420, 430, 440 corresponds to the particular locations of the first jamb member 310, the second jamb member 312, the head member 314, and the sill member 316 in FIG. 3. As shown in FIG. 10, the first corner 410 comprises a notched head member 412 and a notched second jamb member 414. The second corner 420 comprises a second notched head member 422 and a notched first jamb member 424. The third corner 430 comprises a second notched first jamb member 434 and a notched sill member 432. Finally, the fourth corner 440 comprises a second notched sill member 442 and a second notched second jamb member 444. The corners 410, 420, 430, 440 may comprise any design of the first jamb member 310, the second jamb member 312, the head member 314, and the sill member 316 previously discussed and shown in FIGS. 4A, 4B, 5A, 5B, 7A, 7B, 7C, 8A, 8B, and 8C. For example, the first corner 410 may comprise a notched head extension 1314 and a notched jamb receiver 1312; the second corner 420 may comprise a second notched head extension 1314 and a notched jamb extension 1310; the third corner 430 may comprise a second notched jamb extension 1310 and a notched sill receiver 1316; and the fourth corner 440 may comprise a second notched sill receiver 1316 and a second notched jamb receiver 1312. In this example, the head extension 1314 fits between the first corner 410 and the second corner 420. The jamb extension 1310 fits between the second corner 420 and the third corner 430. The sill receiver 1316 fits between the third corner 430 and the fourth corner 440. Finally, the jamb receiver 1312 fits between the fourth corner 440 and the first corner 410.
Alternatively, the frame 210 design may omit the first corner 410, second corner 420, third corner 430, and fourth corner 440. Instead, the frame 210 may include a notched first jamb member 310 and a notched second jamb member 312. In this embodiment, the notched first jamb member 310 and the notched second jamb member 312 join with the head member 314 and/or sill member 316 at the corners of the frame 210.
FIG. 11 is a front, left perspective view of an exemplary notched first jamb angle 2310 and a head angle 2314. The frame 210 may include a notched first jamb angle 2310 which joins with a head angle 2314 to form a corner of the frame 210, as shown in FIG. 11. Alternatively, the head member 314 and/or sill member 316 may be notched. In this embodiment, the notched head member 314 and/or the notched sill member 316 join with the first jamb member 310 and/or second jamb member 312 at the corners of the frame 210.
The frame 210 may be made from aluminum, galvanized steel, vinyl, or any other rigid material having properties that meet the design needs. The frame 210 may be non-loadbearing. The vast types of materials suitable to construct the wall panel 100 enable the wall panel 100 to be used in various types of structures. Although the wall panel 100 is depicted as rectangular in shape, the wall panel 100 and its components may be designed to conform to alternative shapes. Moreover, the materials suitable to construct the wall panel 100 can be relatively inexpensive and enable more affordable wall panel 100 and wall panel system designs. The components of the wall panel 100 may be prefabricated and pre-assembled in a factory, or any appropriate location. Once on site, the wall panels 100 require little or no additional components or assembly, allowing for quick and simple wall panel 100 installation on site.
FIG. 12 is a flow chart of a method of assembling the wall panel 1200.
In step 1210, the components of a wall panel 100, including an exterior infill component 200, an interior structural component 220, and a frame 210, are received. The frame 210 includes a first jamb member 310, a second jamb member 312, a head member 314, and a sill member 316. The components, features, and embodiments of a wall panel 100 are the same as previously described. In step 1220, the frame 210 is connected to the interior structural component 220. In step 1230, the exterior infill component 200 is also connected to the interior structural component 220.
More specifically, a method of assembling a wall panel 1202 may include the step 1212 of receiving a cladding component 202, a plurality of furring strips 204, an insulation component 206, a frame 210, a weather barrier 222, a structural sheathing component 224, and a structural frame 226. The structural frame 226 may comprise a bottom plate 228, a top plate 227, and a plurality of vertical studs 229. Step 1222 includes attaching the structural sheathing component 224 to the structural frame 226. Step 1224 includes attaching the weather barrier 222 to the structural sheathing component 224. Step 1226 includes attaching the frame 210 to the structural sheathing component 224. Step 1232 includes pinning the insulation component 206 to the weather barrier 222 with the plurality of furring strips 204. Step 1234 comprises attaching the plurality of furring strips 204 to the structural sheathing component 224. Step 1236 comprises attaching the cladding component 202 to the plurality of furring strips 204.
FIG. 13 is a front, right perspective view of a wall panel system 600, shown partially installed. A wall panel system 600 includes a plurality of wall panels 100 connected via the wall panel frames 210. The wall panel system 600 is shown in detail in FIGS. 13-19. FIGS. 13-19 depict an exemplary wall panel system 600 with four wall panels 100a-d. However, a wall panel system 600 may include additional wall panels 100. Each wall panel 100 of the wall panel system 600 includes the same features, components, and embodiments of the wall panel 100 previously discussed in detail.
The wall panel system 600 includes adjacently aligned connected wall panels 100 as well as stacked connected wall panels 100. The exemplary wall panel system 600 includes a first wall panel 100a aligned adjacently with a second wall panel 100b and a third wall panel 100c aligned adjacently with a fourth wall panel 100d. Additionally, the third wall panel 100c is stacked on top of the first wall panel 100a, and the fourth wall panel 100d is stacked on top of the second wall panel 100b. The first wall panel 100a and the third wall panel 100c are vertically aligned, and the second wall panel 100b and the fourth wall panel 100d are vertically aligned.
FIGS. 14A-C depict alternative embodiments of the first wall panel 100a according to the different designs of the frame 210 previously discussed. FIG. 14A is a front, left perspective view of a first embodiment of the top left portion of a first wall panel. FIG. 14A shows a section of a first wall panel 100a including a head extension 1314a as the head member 314 of the first wall panel 100a and a jamb receiver 1312a as the second jamb member 312 of the first wall panel 100a.
FIG. 14B is a front, left perspective view of a second embodiment of the first wall panel. FIG. 14C is a front, left perspective view of a third embodiment of the first wall panel. FIGS. 14B and 14C show a first wall panel 100a including a head angle 2314a as the head member 314 of the first wall panel 100a and a second jamb angle 2312a as the second jamb member 312 of the first wall panel 100a.
In the wall panel system 600, the first jamb member 310 of a wall panel 100 mates with the second jamb member 312 of an adjacent wall panel 100. For example, in the exemplary four wall panel 100a-d wall panel system 600, the second jamb member 312 of the first wall panel 100a mates with the first jamb member 310 of the second wall panel 100b, and the second jamb member 312 of the third wall panel 100c mates with the first jamb member 310 of the fourth wall panel 100d.
FIG. 15A is a front, left perspective view of a first embodiment of the top portion of a second wall panel 100b installed with the first wall panel 100a of FIG. 14A. FIG. 15A shows a jamb extension 1310b as the first jamb member 310 of the second wall panel 100b and a head extension 1314b as the head member 314 of the second wall panel 100b. FIG. 15A shows the jamb extension 1310b of the second wall panel 100b mating with the jamb receiver 1312a of the first wall panel 100a
FIG. 15B is a front, left perspective view of a second embodiment of the second wall panel installed with the first wall panel of FIG. 14B. FIG. 15B shows a first jamb angle 2310b as the first jamb member 310 of the second wall panel 100b and a head angle 2314b as the head member 314 of the second wall panel 100b. FIG. 15B shows the first jamb angle 2310b of the second wall panel 100b mating with the second jamb angle 2312a of the first wall panel 100a.
FIG. 15C is a front, left perspective view of a third embodiment of the second wall panel 100b installed with the first wall panel 100a of FIG. 14C. FIG. 15C shows a first jamb angle 2310b as the first jamb member 310 of the second wall panel 100b and a head angle 2314b as a head member 314 of the second wall panel 100b. The head members 314 of the first wall panel 100a and the second wall panel 100b also includes a T-shaped head extension 3314. The T-shaped head extension 3314 may span a portion of the first wall panel 100a and the second wall panel 100b as shown in FIG. 15C. Alternatively, there may be multiple T-shaped head extensions 3314 wherein a first T-shaped head extension 3314 spans the first wall panel 100a and a second T-shaped head extension 3314 spans the second wall panel 100b. FIG. 15C shows the first jamb angle 2310b of the second wall panel 100b mating with the second jamb angle 2312a of the first wall panel 100a.
In the wall panel system 600, the head member 314 of a wall panel 100 mates with the sill member 316 of a stacked wall panel 100. For example, in the exemplary four wall panel 100a-d wall panel system 600, the head member 314 of the first wall panel 100a mates with the sill member 316 of the third wall panel 100c, and the head member 314 of the second wall panel 100b mates with the sill member 316 of the fourth wall panel 100d.
FIG. 16A depicts a third wall panel 100c stacked on the first wall panel 100a of FIG. 15A. The third wall panel 100c includes a sill receiver 1316c as the sill member 316 and a jamb receiver 1312c as a second jamb member 312. FIG. 16A shows the sill receiver 1316c of the third wall panel 100c mating with the head extension 1314a of the first wall panel 100a.
FIG. 16B depicts a third wall panel 100c stacked on the first wall panel 100a of FIG. 15B. The third wall panel 100c includes a sill angle 2316c as the sill member 316 and a second jamb angle 2312c as the second jamb member 312. FIG. 16B shows the sill angle 2316c of the third wall panel 100c mating with the head angle 2314a of the first wall panel 100a.
FIG. 16C depicts a third wall panel 100c stacked on the first wall panel 100a of FIG. 15C. The third wall panel 100c includes a brake-formed sill receiver 3316c as the sill member 316 and a second jamb angle 2312c as the second jamb member 312. FIG. 16C shows the brake-formed sill receiver 3316c of the third wall panel 100c mating with the combined head angle 2314c of the first wall panel 100a and the T-shaped head extension 3314.
FIGS. 17A-C correspond with FIGS. 16A-C and depict alternative embodiments according to the different designs of the frame 210 previously discussed. FIG. 17A is a front, left perspective view of a first embodiment of the bottom portion of a fourth wall panel 100d installed with the first wall panel 100a, the second wall panel 100b, and the third wall panel 100c of FIG. 16A. FIG. 17A depicts a fourth wall panel 100d adjacent to the third wall panel 100c and stacked on the second wall panel 100b. The fourth wall panel 100d includes a jamb extension 1310d as the first jamb member 310 and a sill receiver 1316d as the sill member 316. FIG. 17A shows the jamb extension 1310d of the fourth wall panel 100d mating with the jamb receiver 1312c of the third wall panel 100c, and the sill receiver 1316d of the fourth wall panel 100d mating with the head extension 1314b of the second wall panel 100b.
FIG. 17B is a front, left perspective view of a second embodiment of the fourth wall panel 100d installed with the first wall panel 100a, the second wall panel 100b, and the third wall panel 100c of FIG. 16B. FIG. 17B depicts a fourth wall panel 100d adjacent to the third wall panel 100c and stacked on the second wall panel 100b. The fourth wall panel 100d includes a first jamb angle 2310d as the first jamb member 310 and a sill angle 2316d as the sill member 316. FIG. 17B shows the first jamb angle 2310d of the fourth wall panel 100d mating with the second jamb angle 2312c of the third wall panel 100c, and the sill angle 2316d of the fourth wall panel 100d mating with the head angle 2314b of the second wall panel 100b.
FIG. 17C is a front, left perspective view of a third embodiment of the fourth wall panel 100d installed with the first wall panel 100a, the second wall panel 100b, and the third wall panel 100c of FIG. 16C. FIG. 17C depicts a fourth wall panel 100d adjacent to the third wall panel 100c and stacked on the second wall panel 100b. The fourth wall panel 100d includes a first jamb angle 2310d as the first jamb member 310 and a brake-formed sill receiver 3316d as the sill member 316. FIG. 17C shows the first jamb angle 2310d of the fourth wall panel 100d mating with the second jamb angle 2312c of the third wall panel 100c, and the brake-formed sill receiver 3316d of the fourth wall panel 100d mating with the head angle 2314b of the second wall panel 100b and the T-shaped head extension 3314 (not visible in FIG. 17C) spanning the first wall panel 100a and the second wall panel 100b as shown in FIGS. 15C and 16C.
As shown in FIG. 14A-17C, the wall panels 100a-d connect together via the wall panel 100 frame 210. Although FIGs. designated A, B, and C show three alternative embodiments, variations of the frame 210 according to design options previously discussed may lead to additional possible embodiments. Any of the first jamb member and second jamb member combinations shown in FIGS. 6A-6C may be paired with any head member and sill member combinations shown in FIGS. 9A-9C to form the frame 210 of the wall panel 100. Wall panels 100 fit together according to the different design options.
A cross-section view of the of the first jamb member 310 and the second jamb member 312 joint between adjacent wall panels 100 is shown in FIGS. 18A and 18B. FIG. 18A is a plan view of a first embodiment of adjacent wall panels 100 of the wall panel system 600. FIG. 18A depicts a plan view of an exemplary joint between two adjacent wall panels 100 in which the first jamb member 310 is a jamb extension 1310 and the second jamb member 312 is a jamb receiver 1312.
FIG. 18B is a plan view of a second embodiment of adjacent wall panels 100 of the wall panel system 600. FIG. 18B depicts a plan view of a second exemplary joint between two adjacent wall panels 100 in which the first jamb member 310 is a first jamb angle 2310 and the second jamb member 312 is a second jamb angle 2312.
As shown in FIGS. 18A and 18B, the wall panel system 600 may also include seals or gaskets 502. The wall panel system 600 may include seals or gaskets 502 between the second jamb member 312 and the first jamb member 310 of adjacent wall panels 100. The seals or gaskets 502 weatherproof the wall panel system 600 by preventing water and air from entering the joint.
A cross-section view of the head member 314 and the sill member 316 joint between stacked wall panels 100 is shown in FIGS. 19A-C. FIG. 19A is a cross-section view of a first embodiment of stacked wall panels 100 of the wall panel system 600. FIG. 19A depicts a cross-section view of an exemplary joint between two stacked wall panels 100 in which the head member 314 is a head extension 1314 and the sill member 316 is a sill receiver 1316.
FIG. 19B is a cross-section view of a second embodiment of stacked wall panels 100 of the wall panel system 600. FIG. 19B depicts a cross-section view of a second exemplary joint between two stacked wall panels 100 in which the head member 314 is a head angle 2314 and the sill member 316 is a sill angle 2316.
FIG. 19C is a cross-section view of a third embodiment of stacked wall panels 100 of the wall panel system 600. FIG. 19C depicts a cross-section view of a third exemplary joint between two stacked wall panels 100 in which the head member 314 is combination of a head angle 2314 and a T-shaped head extension 3314 and the sill member 316 is a brake-formed sill receiver 3316.
As shown in FIGS. 19A-C, the wall panel system 600 may also include seals or gaskets 504. The wall panel system 600 may include seals or gaskets 504 between the head member 314 and the sill member 316 of stacked wall panels 100. The seals or gaskets 504 weatherproof the wall panel system 600 by preventing water and air from entering the joint.
FIG. 20 is a front, left perspective view of the intersection of the wall panel system 600 showing the seals or gaskets 502, 506 and the silicone tape 508. More specifically, FIG. 20 shows the intersection of four wall panels 100a-d. The wall panel system 600 may include seals or gaskets 506 between the head members 314 of adjacent wall panels 100. Moreover, the wall panel system 600 may include tape 508 over the head members 314 of adjacent wall panels 100. The tape 508 may be silicone tape, any flexible self-adhered membrane, or flexible membrane adhered with sealant. The membrane can be made from a plurality of materials available. Mating four wall panels 100a-d forms a joint or intersection in the shape of a “cruciform” or “+” sign, as shown in FIG. 20. The seals or gaskets 502, 504 (not visible in FIG. 20), 506 and the tape 508 weatherproof the “cruciform” or “+” sign joint of the wall panel system 600.
FIG. 21 is a flow chart of a method of installing the wall panel system 2100. The method of installing an exemplary four wall panel 100a-d wall panel system 2100 can be carried out according to the method 2100 described in FIG. 21 and described below.
In step 2110, the components of a wall panel system 600, as described above, are received.
In step 2120, the first wall panel 100a is installed, as shown in FIGS. 14A-C, and secured to a plurality of anchors.
In step 2130, the second wall panel 100b is installed adjacent to the first wall panel 100a, as shown in FIGS. 15A-C, by placing the first jamb member 310 of the second wall panel 100b along the second jamb member 312 of the first wall panel 100a. The second wall panel 100b is also secured to a second plurality of anchors.
In step 2140, the third wall panel 100c is stacked on top of the first wall panel 100a, as shown in FIGS. 16A-C, by placing the sill member 316 of the third wall panel 100c across the head member 314 of the first wall panel 100a, until the third wall panel 100c is vertically aligned with the first wall panel 100a.
Finally, in step 2150, the fourth wall panel 100d is stacked on top of the second wall panel 100b, as shown in FIGS. 17A-C, by placing the first jamb member 310 of the fourth wall panel 100d along the second jamb member 312 of the third wall panel 100c, until the sill member 316 of the fourth wall panel 100d meets and aligns with the head member 314 of the second wall panel 100b. Once in position, the fourth wall panel 100d is adjacently aligned with the third wall panel 100c and vertically aligned with the second wall panel 100b.
In one embodiment, the method of installing a wall panel system 2100 may also include installing a T-shaped head extension 3314 before installing the third wall panel 100c. In this embodiment, the T-shaped head extension 3314 is placed across the head member 314 joint of the first wall panel 100a and the second wall panel 100b, as shown in FIG. 15C. Then, the T-shaped head extension 3314 is connected to the head member 314 of the first wall panel 100a and the head member 314 of the second wall panel 100b.
The method of installing a wall panel system 2100 may further include installing gaskets 502, 506 between the second jamb member 312 of the first wall panel 100a and the first jamb member 310 of the second wall panel 100b, the second jamb member 312 of the third wall panel 100c and the first jamb member 310 of the fourth wall panel 100d, and finally, between the head member 314 of the first wall panel 100a and the head member 314 of the second wall panel 100b. Gaskets 504 may also be installed between the head member 314 of the first wall panel 100a and the sill member 316 of the third wall panel 100c and between the head member 314 of the second wall panel 100b and the sill member 316 of the fourth wall panel 100d.
The method of installing a wall panel system 2100 may also comprise installing silicone tape 508 over the head member 314 of the first wall panel 100a and the head member 314 of the second wall panel 100b.
When a plurality of wall panel systems 600 are installed on the job site, the first level, comprising the first wall panel 100a and the second wall panel 100b of each wall panel system 600, is installed around the perimeter of the structure according to steps 2110, 2120, and 2130 of method 2100 described above. Then, the second level, comprising the third wall panel 100c and the fourth wall panel 100d of each wall panel system 600, is installed on top of the first level around the perimeter of the structure according to steps 2140 and 2150. Any additional levels will also be installed according to steps 2140 and 2150.
This method of installation 2100 is quick and easy and requires minimal equipment. Thus, the wall panel system 600 is cheaper and safer to install than most wall systems.
Having thus described in detail a preferred selection of embodiments of the present invention, it is to be appreciated and will be apparent to those skilled in the art that many physical changes could be made to the wall panel, and the assembly thereof and the wall panel system and the installation thereof, without altering the inventive concepts and principles embodied therein. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore to be embraced therein.
Patent Application
20200131761
