WATERPROOFING AND SAFETY-INCREASING PREFABRICATED BUILDING FRAMING SYSTEM AND METHOD

Abstract

A waterproof and safety framing system is disclosed. The framing system includes a building defining an opening, a wall panel, and a framing assembly. The framing assembly includes receiver and a bottom track. The receiver is installed along an edge of the opening, with the receiver including a receiver bottom wall that defines a receiver ridge extending along a length of the receiver. The bottom track is attached to an edge of the wall panel and including a track bottom wall that defines a track ridge, with the receiver and the bottom track matingly engaging such that the bottom track overlays the receiver and the receiver ridge and the track ridge are proximal one another. The framing assembly is structured to prevent the wall panel from passing through the opening in a first direction.

Description

BACKGROUND OF THE INVENTION

The present invention relates to prefabricated exterior wall installations and, more particularly, to a system and method for providing a waterproofed and secure exterior wall panel installation from an interior of a building.

Prefabricated, structural cold-formed metal framing (CFMF) bearing walls are quickly becoming a popular construction system choice in large part due to this system being economical in comparison to other systems, such as reinforced concrete or structural steel. When installing prefabricated exterior wall panels from the interior of a building, in particular, in a slab-to-slab condition, there is no way to waterproof the installation without accessing the exterior of the building. This is particularly a challenge when the installation is not occurring on the ground level of the building.

With traditional installation methods of exterior prefabricated wall panels, gaps at the floor, head and edges of the installed panels allow for water infiltration prior to accessing the exterior of the building to install and air barrier. In addition, the installation of exterior panels from the interior of the building can create an unstable condition to where the exterior panels extend too far outbound of the building and fall to the ground, creating a safety hazard.

As can be seen, there is a need for a system and method for providing a waterproofed exterior wall panel installation from an interior of the building that ameliorates the aforementioned problems, including safety issues.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a framing assembly, for installing a wall panel in an opening of a building, comprises: a receiver configured to be installed along an edge of the opening, the receiver including a receiver bottom wall that defines a receiver ridge extending along a length of the receiver; and a bottom track configured to be attached to an edge of the wall panel and including a track bottom wall that defines a track ridge, the receiver and the bottom track matingly engaging such that the bottom track overlays the receiver and the receiver ridge and the track ridge are proximal one another.

In another aspect of the present invention, a framing system comprises: a building defining an opening; a wall panel; and a framing assembly comprising: a receiver installed along an edge of the opening, the receiver including a receiver bottom wall that defines a receiver ridge extending along a length of the receiver; and a bottom track attached to an edge of the wall panel and including a track bottom wall that defines a track ridge, the receiver and the bottom track matingly engaging such that the bottom track overlays the receiver and the receiver ridge and the track ridge are proximal one another.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation view of an embodiment of the present invention, in use;

FIG. 2 is a detail perspective view of a bottom track of the embodiment of the present invention;

FIG. 3 is a detail perspective view of a receiver of the embodiment of the present invention;

FIG. 4 is a detail perspective view of an angle member of the embodiment of the present invention;

FIG. 5 is a cutaway perspective view of the embodiment of the present invention, showing the interior of a bottom assembly;

FIG. 6 is a detail perspective view of the embodiment of the present invention, showing the interior of a top assembly; and

FIG. 7 is a cross-sectional detail view of the embodiment of the present invention, taken on line 7-7 of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, one embodiment of the present invention is a framing assembly that prevents air and moisture infiltration into a building. The framing assembly includes a bottom track that attaches to a wall panel and a receiver that is installed into an opening in the building. The bottom track and receiver both include ridges that mate when the wall panel is installed in the building opening such that no moisture or air can pass between the bottom track and the receiver. Further provided in the embodiment described herein is structure that prevents the wall panel from falling through the building opening accidentally, increasing the safety for individuals at a job site.

Currently, in the installation of the drywall metal framing, there is an issue of water infiltration that prohibits the start of the drywall process. The invention will alleviate a significant amount of water infiltration when used with a prefabricated or field installed exterior wall. There are a number of manufacturers who currently prefabricate exterior slab-to-slab framing panels, but this still does not prevent water infiltration due to negative pressure at the base and terminations of the wall. In addition, the secondary benefit to the system and method described herein is the ability to prevent the exterior prefabricated panel from accidentally falling from the edge of the building during install as it will create a “frame” around the opening in which the exterior panel is to be installed.

In accordance with certain aspects of the present invention, three fabricated members are installed in a building opening. Two of the three fabricated members may be installed prior to an exterior panel being set in place and the third fabricated member being installed on the prefabricated exterior panel itself, rather than utilizing a customary bottom track. This unique configuration results in a watertight installation of the prefabricated exterior panel despite being installed from the interior of the building. In certain embodiments of the present invention, this result is achieved by utilizing a novel interlocking V-profile track and receiver with angle members fastened at terminations of the wall, which allows for the fabricated members to be waterproofed prior to the exterior panels being installed in the building opening. Thus, the installed assembly is watertight as soon as the exterior panels are installed, and a further benefit of the system discussed herein is that the fabricated members prevent the exterior panels from falling from the building while being installed. The following detailed description will make clear these benefits, and others not yet discussed, of the present invention. It should be understood, of course, that the structure described is exemplary and intended to illustrate core concepts of the present invention, and modifications to the design may be made without departing from the spirit and scope of the present invention as claimed.

Referring to FIGS. 1-7, a waterproof framing system 10 is disclosed. As part of this system 10, a framing assembly 12, an air/moisture barrier 14, and a wall panel 16 are provided. As shown in FIG. 1, the framing assembly 12, air/moisture barrier 14, and wall panel 16, in use, are installed in an opening of a building 18. In certain preferred embodiments of the present invention, the framing assembly 12 may include a bottom track 20, a receiver 22, substantially L-shaped angle members 24. The bottom track, as shown in FIG. 2, may include a track ridge 20a (for example, it may resemble an inverted V-shape and come to a point) extending along a length of the bottom track 20, a track bottom wall 20b, and two oppositely disposed track upper walls 20c extending upwardly from the bottom wall 20b and, in combination with the bottom wall 20b, define a channel. The receiver 22, as shown in FIG. 3, may include a receiver ridge 22a (for example, it may resemble an inverted V-shape and come to a point) extending along a length of the receiver 22, a receiver bottom wall 22b, and a receiver upper wall 22c extending from the receiver bottom wall 22b. The angle members 24, as shown in FIG. 4, may include a first wall 24a and a second wall 24b, with the first wall 24a having a greater width than a width of the second wall 24b. In use, the first wall 24a directly engages the opening. Finally, sealant 26 and sheathing 28 (such as gypsum sheathing) may be provided, as well, as part of the waterproof framing system 10.

In accordance with certain aspects of the present invention, the bottom track 20 may be installed or attached to the panel 16 as the panel 16 itself is being constructed. As shown in FIG. 7, the track upper walls 20c and track bottom wall 20b envelope a bottom edge of the panel 16, with the bottom edge engaging/contacting the track ridge 20a. The purpose of the track ridge 20a (and also the receiver ridge 22a) is to prevent water from gaining access from underneath the track 20 and receiver 22 via negative pressure. Also, the ridges 20a, 22a are there to index the panel 16 and lock in its location in plane based on the architectural drawings.

As further shown in FIG. 7, the receiver 22 is installed at a bottom of the opening of the building 18. An outer portion of the receiver 22 may be treated with the air barrier 14 that seals any gaps between the building 18 and the receiver 22 to ensure water tightness. As shown in FIGS. 5 and 7, the bottom track 20 and receiver 22 have complementary cross-sectional profiles so that the bottom track 20 rests flat on the receiver 22 when the panel 16 with the bottom track 20 is installed in the opening with the receiver 22. When this installation occurs, the respective ridges 20a, 22a align and the receiver ridge 22a nests within the track ridge 20a, with sealant 26 being provided therebetween. Thus, a watertight seal between the bottom track 20 and receiver 22 is formed. As further shown in FIGS. 5 and 7, a lower portion of the sheathing 28, which is attached to an outer side of the panel 16 and overlays at least a portion of one of the track upper walls 20c, extends into a gap defined by one of the track upper walls 20c and the receiver upper wall 22c when the bottom track 20 is installed with the receiver 22. Sealant 26 may be provided between the sheathing 28 and the receiver upper wall 22c to ensure no moisture can penetrate the previously described gap.

In accordance with other aspects of the present invention, and referring to FIGS. 1, 4 and 6, the angle members 24 are used to form a header and jamb for the panels 16. In certain embodiments, an angle member 24 may be used in place of the bottom track 20 and receiver 22, as presently embodied, to serve as a bottom seal structure of the panel 16. However, for reasons outlined above, the bottom track 20 and receiver 22 have various functional benefits that make it superior to the use of an angle member 24. As shown in FIGS. 1 and 6, the angle members 24 are installed in the opening of the building 18 such that the second wall 24b extends from an edge of the opening into the opening, thus ensuring that when the panel 16 is installed, the second wall 24b prevents the panel 16 from falling through the opening. The vertically extending angle members 24 are typically installed at wherever termination of the panels 16 occur, which is generally (but not always) at a column. Referring to FIG. 6, as with the bottom portion of the framing assembly 12, sealant 26 may be used at joints to ensure a watertight seal between the angle members 24 and the building 18. Together, the angle members 24 with the bottom track 20 and receiver 22 result in an air and watertight assembly around the edges of panels 16 installed in buildings 18. The angle members, in particular, have a number of other potential uses, such as other metal framing including ceiling framing or anything that requires an L-shaped sheet metal for install.

While methods of making the present invention would be readily apparent to those with skill in the art from the foregoing disclosure, a method of making embodiments of the present invention may include the following. First, an exterior panel 16 is fabricated in accordance with typical CFMF procedures. Metallic-coated sheet steel may be roll-formed to create the bottom track 20, receiver 22, and angle members 24. The bottom track 20 is then permanently affixed to a bottom edge of the panel 16, and gypsum sheathing 28 may be attached to an outer wall of the panel 16.

Further, while methods of using the present invention would be readily apparent to those with skill in the art from the foregoing disclosure, a method of using embodiments of the present invention may include the following. First, the receiver 22 is installed (using, for example, a shot and pin method) at the base (such as a concrete slab) of an opening in a building 18. Angle members 24 are then installed on a ceiling/header of the opening and at any location where the panels 16 end, such as a concrete column. The receiver 22 and angle members 24 may both be treated with any number of appropriate air barrier systems being used on the building 18. The air barrier 14 bridges the frame assembly 12 of the present invention to the building 18. Next, a bead of sealant 26 is run along outside edges of the receiver 22 and angle members 24 as well as along the receiver ridge 22a. Next, the exterior panel 16, with the bottom track 20 defining a bottom edge thereof, is installed within the opening (with the user installing it from an interior of the building 18), with the bottom track 20 mating with the receiver 22 and other edges of the panel 16 engaging at least one of the angle members 24 (specifically, the second walls 24b). The panel may then be secured in the opening using various techniques. Prior to installing a subsequent panel 16, another bead of sealant 26 is applied to a leading edge of the panel 16 and behind the sheathing 28, as shown in FIG. 1. Next, an adjacent panel 16 is installed by sliding it snugly against the previously installed panel 16 and into the bead of sealant 26. This process may be continued until the opening of the building 18 is enclosed by the panels 16.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.

Claims

1. A method of enclosing an opening defined by one or more structural members of a building structure, comprising: installing a receiver along a base of the opening, the receiver including a receiver bottom wall facing the base of the opening and a receiver upper wall oriented to face an interior of the building structure; andinstalling one or more angle members along a ceiling header of the opening, the one or more angle members including a first wall and a second wall, with the first wall mounted in abutment of a face of the ceiling header, and the second wall protruding into the opening and having an interior face and an exterior face;applying a bottom track to a bottom edge a wall panel, the bottom track having at least one track upper wall and a track bottom wall; andpositioning, from an interior of the building structure, an exterior face of a wall panel in abutment with an interior face of the receiver upper wall and the interior face of the second wall.

2. The method of claim 1, further comprising: installing a subsequent wall panel in abutment with an interior face of the receiver upper wall, the interior face of the second wall of the angle members, and an adjacent edge of an subsequent wall panel.

3. The method of claim 2, further comprising: before installing the subsequent wall panel, applying a sealant along a lateral edge of the wall panel; andpressing the adjacent edge of the subsequent wall panel into the sealant.

4. The method of claim 3, further comprising: installing additional subsequent wall panels until the opening of the building structure is enclosed.

5. The method of claim 1, further comprising: applying the one or more angle members to the wall panel as one or more of a header and a jamb for the wall panel.

6. The method of claim 1, further comprising: nesting a ridge defined in the receiver bottom wall with a corresponding ridge defined in the track bottom wall.

7. The method of claim 6, further comprising: applying a sealant between the ridge in the receiver bottom wall and the corresponding ridge in the track bottom wall before nesting.

8. The method of claim 1, further comprising: attaching a sheathing to the exterior face of the wall panel.

9. The method of claim 8, further comprising: applying a sealant between the sheathing and the receiver upper wall.

10. The method of claim 1, further comprising: installing a vertically extending angle member at a termination of side edge of the wall panel.

11. The method of claim 1, further comprising: applying an air barrier to bridge between an exterior face of one or more of the receiver and the one or more angle members and an exterior face of the structural members.

12. A method of enclosing an opening defined by one or more structural members forming a building structure, the method comprising: installing a receiver along a base of the opening, the receiver including a receiver bottom wall adapted for permanent attachment with the base and a receiver upper wall distending therefrom and having an interior face oriented towards an interior of the building structure and generally orthogonal with the base; andinstalling one or more angle members along a ceiling header of the opening, the one or more angle members including a first wall adapted for permanent attachment with the ceiling header and a second wall distending therefrom, the second wall having an interior face oriented towards the interior of the building structure and generally orthogonal with the ceiling header;attaching a bottom track to a bottom edge of a wall panel, the bottom track having at least one track upper wall and a track bottom wall; andpositioning, from an interior of the building structure, an exterior face of the wall panel proximal with the interior face of the receiver upper wall and the interior face of the second wall.

13. The method of claim 12, further comprising: securing the wall panel in the opening, via one or more fasteners.

14. The method of claim 12, wherein the base is a concrete slab.

15. The method of claim 12, further comprising: installing, from the interior of the building structure, an exterior face of a subsequent wall panel proximal with the interior face of the receiver upper wall and the interior face of second wall, the subsequent wall panel positioned adjacent to the wall panel.

16. The method of claim 15, further comprising: sliding the subsequent wall panel along the receiver, to position a lateral side edge of the subsequent wall panel in abutment with an adjacent lateral side edge of the wall panel.

17. The method of claim 16, further comprising: before installing the subsequent wall panel, applying a sealant along one of the lateral side edge of the wall panel or the lateral side edge of the subsequent wall panel; andpressing the lateral side edge of the subsequent wall panel into the sealant.

18. The method of claim 16, further comprising: installing a vertically extending angle member at a termination of the lateral side edge of the wall panel or the subsequent wall panel.

19. The method of claim 12, further comprising: applying the one or more angle members to the wall panel as one or more of a header and a jamb for the wall panel.

20. The method of claim 12, further comprising: nesting a ridge defined in the receiver bottom wall with a corresponding ridge defined in the track bottom wall.

21. The method of claim 20, further comprising: applying a sealant between the ridge in the receiver bottom wall and the corresponding ridge in the track bottom wall before nesting.

22. The method of claim 12, further comprising: attaching a sheathing to the exterior face of the wall panel.

23. The method of claim 22, further comprising: applying a sealant between the sheathing and the receiver upper wall.

24. The method of claim 12, further comprising: applying an air barrier to bridge between an exterior face of one or more of the receiver, the one or more angle members, and an exterior face of the one or more structural members of the building structure.

25. A method of enclosing an opening defined by one or more structural members forming a building structure, the method comprising: installing, from an interior of the building structure, a wall panel forming an exterior cladding of the building structure, the wall panel having a vertical extent to span between a base of the opening and a ceiling header of the opening and dimensioned to close at least a portion of a lateral extent of the opening, the installing comprising:positioning a track disposed along a bottom edge of the wall panel in a receiver disposed in the base of the opening, the receiver having an interior face oriented towards an interior of the building structure and generally orthogonal with the base, the receiver coupled with the base to retain the wall panel with the building structure; androtating the wall panel about the bottom edge of the wall panel towards the exterior of the building structure until a top edge of the wall panel is positioned in abutment with an interior face of an angle member protruding into the opening from the ceiling header of the building structure, the interior face oriented towards the interior of the building structure and generally orthogonal with the ceiling header, the angle member coupled with the base to retain the wall panel with the building structure.

26. The method of claim 25, wherein the wall panel is a structural cold-formed metal framing (CFMF) bearing wall.

27. The method of claim 25, further comprising: positioning a subsequent track, disposed along the bottom edge of a subsequent wall panel, in the receiver; androtating the subsequent wall panel about the bottom edge until the top edge of the subsequent wall panel is in abutment with the interior face of the angle member. member second wall, the subsequent wall panel positioned adjacent to the wall panel.

28. The method of claim 27, further comprising: sliding the subsequent wall panel along the receiver, to position a lateral side edge of the subsequent wall panel in abutment with an adjacent lateral side edge of the wall panel.

29. The method of claim 28, further comprising: before installing the subsequent wall panel, applying a sealant along one of the lateral side edge of the wall panel or the lateral side edge of the subsequent wall panel; andembedding the other of the lateral side edge of the wall panel or the lateral side edge of the subsequent wall panel in the sealant.

30. The method of claim 25, further comprising: applying the one or more angle members to the wall panel as one or more of a header and a jamb for the wall panel.

31. The method of claim 25, further comprising: nesting a ridge defined in a receiver bottom wall with a corresponding ridge defined in a bottom wall of the track.

32. The method of claim 31, further comprising: applying a sealant between the ridge in the receiver bottom wall and the corresponding ridge in the bottom wall of the track before nesting.