US20070251181A1

US20070251181A1 - Panel attachment system

Info

Publication number: US20070251181A1
Application number: US11/742,027
Authority: US
Inventors: Louis Dupont
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-05-01
Filing date: 2007-04-30
Publication date: 2007-11-01
Also published as: CA2573008A1

Abstract

A panel attachment system for mounting panels to construct a wall structure generally utilizes interconnecting panel assemblies comprising panels with frames attached thereto. Each frame includes a generally outwardly facing channel disposed proximate the perimeter of the panel for receiving a spline member used to interconnect adjacent panel assemblies. Preferably, the spline members secure adjacent panel assemblies together and seal abutting edges of the adjacent pieces of the resulting wall structure. Connection members, such as molding pieces, including at least one generally outwardly facing channel for receiving a spline member can be used to connect adjacent panel assemblies or to finish an edge of a panel assembly.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 60/796,832, filed May 1, 2006, and Canadian Application No. 2,573,008, filed Jan. 5, 2007, both of which are entitled “PANEL ATTACHMENT SYSTEM”. Applicant claims priority of both of the above-identified applications which are incorporated herein by reference.

FIELD OF THE INVENTION

The invention generally relates to a panel attachment system for mounting panels to construct a wall structure or the like, and more specifically relates to a panel attachment system using a series of interconnecting panel assemblies mountable to a building structure to construct a wall structure or the like.

BACKGROUND OF THE INVENTION

Many systems for constructing walls in both the interior and exterior of buildings exist in prior art. Most such systems involve lengthy and laborious, occasionally multi-step, processes and achieve varying degrees of results. For instance, a common multi-step process calls for wall panels to be screwed to the building exterior. The seams and screw heads are then covered with a cement product, the corners reinforced with mesh and similarly covered, and the entire surface is coated with the desired finishing material. Later, thermal expansion joints must be cut and filled with a resilient architectural-grade caulk to protect against structural damage due to the effects of thermal expansion and contraction on the wall panels. Such a process is costly and requires workers to make a minimum of three separate trips to the building site to complete installation of a finished wall. A further drawback of such a multi-step process is that the finishing step must be performed when temperatures will remain above freezing due to the threat of surface cracking from thermal expansion and contraction, and therefore limits the construction timeline, especially in colder climates.
A similar method for constructing walls and particularly interior walls includes building a wall frame using vertically disposed wooden, metallic or polymeric composite frame pieces or studs, and then securing panels of wall-lining material, such as wallboard, to the wall frame. The panels are often secured to the wall frame using common fasteners, such as wallboard screws or nails. To ensure a flat and smooth wall, the fasteners are liberally applied—often screws are used to attach each panel at multiple places about the area of the panel corresponding to each stud positioned behind the panel. The seams and screw heads need to be covered with a cement or plaster product, and the corners need to be reinforced with mesh and similarly covered. The entire surface of the wall may be coated with a desired finishing material. Again, such a process takes multiple steps to achieve a finished wall, and accordingly is time consuming and costly.
Existing panel mounting systems involving the attachment of panels to a pre-built frame structure use alternate means for mounting the panels to the wall frame. For example, U.S. Pat. No. 6,951,087 discloses a frame structure comprising vertical C-profiles mounted with respect to similarly shaped horizontal C-profiles to form a grid-like wall frame structure. Bracket clips are then attached to the vertical C-profiles at equivalent heights and form the support for horizontally positioned Z-rails. The wall is then formed by attaching panels directly to the grid frame by fastening them to the Z-rails. However, such a system merely provides a means to mount panels to the pre-built frame structure, and does not obviate the need to seal the seams and screw holes after the panels have been mounted.
Other inventions exist that disclose systems for attaching adjacent panels in a wall structure to each other using clips or similar devices to secure their connection and the stability of the entire wall. For instance, U.S. Pat. No. 3,837,133 discloses a clip device employed to hold adjacent panels together to enable such panels to be attached to nearby wall studs. Again, such devices focus on mounting the panels to a wall frame, but do not eliminate the need to seal and finish the wall after the panels have been mounted.
Accordingly, a need exists for a panel attachment system that not only provides for easy and secure attachment of wall panels to a wall structure or frame, but that also reduces and even eliminates the costly and time consuming steps associated with positioning and connecting adjacent panels, and then sealing and finishing the panels after mounting. The present invention eliminates the drawbacks of prior art wall paneling systems while reducing the time of construction. The present invention has the advantages of allowing the erection of fully functional, weatherproofed walls in one pass without the need to further treat the wall structure, thus eliminating shortcomings of previously disclosed systems.

SUMMARY OF THE INVENTION

The present invention provides a panel attachment system for constructing a wall structure that comprises at least one panel assembly and at least one spline member to interconnect the panel assembly to an adjacent portion of the wall structure. The panel assembly comprises a panel having a perimeter, a front face and a rear face, and a frame attached to the rear face of the panel and including a generally outwardly facing channel disposed proximate the perimeter of the panel. The spline member is insertable into the channel of the frame to interconnect the corresponding panel assembly to an adjacent portion of the wall structure, such as another panel assembly or a molding element.
In an embodiment of the present invention, the panel attachment system comprises a plurality of panel assemblies, wherein each panel assembly comprises a panel having a perimeter, a front face and a rear face, and a frame attached to the rear face of the panel and including a generally outwardly facing channel disposed proximate the perimeter of the panel. The channels along abutting edges of adjacent panel assemblies face one another such that the adjacent panel assemblies are interconnected via a spline member placed within respective facing channels.
Preferably, the panels have a rectangular perimeter, but panels for use with the present invention may be constructed of various shapes and dimensions in accordance with the design of the wall that the panels are being used to construct. In preferred embodiments, the frame has a perimeter shape that corresponds to the perimeter shape of the panel to which it is attached, and the channels in the frames are disposed proximate the edges of the panels.
In an alternate embodiment, the present invention is directed to a frame structure for attachment to pre-fabricated wall panels to form panel assemblies that can be interconnected using spline members insertable into channels defined in frame members that form the frame.
In an alternate embodiment of the present invention, connection members, such as molding pieces, including at least one generally outwardly facing channel for receiving a spline member can be used to connect adjacent panel assemblies or to finish an edge of a panel assembly.
In constructing a wall using the panel attachment system of the present invention, a first panel assembly is mounted to a wall frame structure. A spline member is inserted into a channel in the frame of the first panel assembly. A second panel assembly, or alternatively, a connection member or a molding piece is mounted to the wall frame structure with the spline member being inserted into a channel adjacent to and facing the first panel assembly. Additional panel assemblies or connection members/molding pieces may be added and interconnected using additional spline members to secure and seal abutting edges of the adjacent pieces of the wall structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic view of a panel attachment system in accordance with the present invention.

FIG. 2 shows a schematic view of the rear face of a panel assembly used in the panel attachment system.

FIG. 3 shows a side profile of an embodiment of the panel assembly of FIG. 2.

FIG. 4 shows an embodiment of a section of a frame track including a generally U-shaped channel for use with a panel assembly of the present invention.

FIGS. 5A-5E show several embodiments of spline members used to attach adjacent components of a panel attachment system of the present invention.

FIGS. 6A-6D show several embodiments of molding components for use with a panel attachment system of the present invention.

FIGS. 7A-7C show a series of partial side views of the interconnection of adjacent molding components.

FIGS. 8A and 8B show respective schematics of the front face and the rear face of the panel attachment system of the present invention installed to create a wall structure showing the interconnection of several panel assemblies.

FIGS. 9A and 9B show enlarged views of the areas A and B of the panel attachment system of FIGS. 8A and 8B, respectively, with the spline member shown in hidden lines.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIG. 1, a panel attachment system for constructing a wall structure in accordance with the present invention is shown generally as reference number 10. The system generally comprises a plurality of panel assemblies that may be interconnected to form the wall structure. As illustrated in FIG. 1, a first panel assembly 12 a is interconnected with an adjacent second panel assembly 12 b via a spline member 14. A molding piece 16 can be interconnected at the edges of the panel assemblies 12 a and 12 b using a spline member 14. The molding piece 16 could also be designed as a connection member to be positioned between panel assemblies and interconnected thereto with spline members.
Preferably, the general structure of panel assemblies in the system 10 (as described herein) is identical. However, the size, shape and appearance of the panel assemblies can vary depending on the shape and design of the wall and/or room, as well as other variables, such as the presence of a window or door in the wall. In preferred embodiments of the panel attachment system 10, adjacent panel assemblies 12 a and 12 b are interconnected so that the respectively adjacent edges of panels mounted thereon essentially abut one another. The interconnecting spline member 14 provides an adequate, preferably weatherproof, seal for the joint or seam between the panel assemblies 12 a and 12 b and eliminates the need to seal or otherwise finish the panels after interconnection. The presence of the spline member 14 between adjacent panel assemblies 12 a and 12 b also means that the abutting edges of the panels need not be flush, and certain design features, such as grooves or spaces between panels may be incorporated into the wall design without sacrificing the seal between the panels. Though additional finishing steps may be taken, such as painting the panels or adding decorative grout between abutting panel edges, a finished wall structure can be constructed using the present invention in a single construction step involving mounting pre-painted panel assemblies to a wall frame and interconnecting them using spline members 14. Such a single step process is especially useful for constructing exterior walls of building structures where the wall panels often comprise pre-finished concrete, marble, stone, or composite panels. The specific assembly of the components of the panel attachment system 10 using spline members 14 to construct a wall structure is discussed in more detail below.
As shown in FIG. 1, panel assemblies 12 a and 12 b have like structure. Accordingly, discussion of the preferred components of a panel assembly of the present invention is provided with respect to a generic panel assembly 12 illustrated in FIG. 2.
Each panel assembly 12 of a preferred panel attachment system 10 comprises a panel 18 and a frame 20. Each panel 18 has a front face 22, a rear face 24 and a perimeter 26 that generally defines the outer edges of the panel 18. Panels for use with the panel attachment system 10 can be made of any common panel material for either interior or exterior application to construct a wall structure, including wallboard, wood, plaster board, concrete, marble, stone-work, composite material, or the like.
The frame 20 comprises at least one track member 28 that defines a channel 30. In a preferred embodiment, the channel 30 has a generally U-shaped cross section, but may have any form provided it sufficiently interacts with the spline member 14 as described herein. The track member 28 is attached to the rear face 24 of the panel 18 so that the generally U-shaped channel 30 is positioned proximate the perimeter 26 of the panel 18 to which the frame 20 is attached and so that the generally U-shaped channel 30 faces outward from the frame 20 toward the edges of the panel 18. The frame 20 is preferably made of a rigid material that provides the panel assembly 12 with adequate stability. For example, the track members 28 can be manufactured from high-gauge galvanized steel or a similar material that will stabilize the wall panel 18 attached thereto. An additional stabilizing track 32 can be added to the frame 20 to increase the rigidity thereof. Additional rigidity is useful for increasing the effectiveness of mounting large panels, and especially heavy panels, such as those typically used for exterior wall applications. In the embodiment illustrated in FIG. 2, the stabilizing track 32 is vertically positioned through the center of the frame 20, and attached, commonly by welding, at a position approximately equidistant from the side edges the frame 20. Alternatively, the stabilizing track 32 can be horizontally or diagonally disposed, or multiple stabilizing tracks can be used in a variety of vertical, horizontal or diagonal positions, or a combination thereof, depending on the design of the frame 20. As illustrated, the stabilizing track 32 has the U-shaped channel design as used along the perimeter of the frame 20. However, the stabilizing track 32 does not require the U-shaped channel and can be any design sufficient to stabilize and add desired rigidity to the frame 20.
In a preferred design of the panel assembly 12, the perimeter 26 of the panel 18 defines a rectangular shape with four edges in accordance with common supplies of wall panels available on the market. The frame 20 preferably has a corresponding rectangular perimeter shape and a generally outwardly facing channel 30 defined along each side of the frame perimeter such that the channels 30 are disposed proximate each of the edges of the panel 18. As shown in FIG. 2, the frame 20 comprises four track members 28, each defining a generally U-shaped channel 30. The track members 28 can be connected to form the frame 20 by any known means, such as welding. Though the general shape of the panel 18 and the corresponding frame 20 is rectangular, panel assemblies 12 in accordance with the present invention can be constructed of any size, shape or dimension, especially if the specific design of the wall structure to be construed requires panels of specific size, shape or dimension. The edges of the panel 18 also need not be straight, and could incorporate any desired design elements, including curved, waved or serrated edges, provided the edge of the adjacent panel has a substantially complementary shape to facilitate construction of the wall. Even in situations where the size, shape or dimension of the panels or the design of the edges of the panel vary, the generally outwardly facing U-shaped channels 30 defined in the frame 20 should be disposed proximate the edges of the perimeter 26 of the panel 18 so as to facilitate interconnection of adjacent panel assemblies 12 using spline members 14. Indeed, where the edges of adjacent panels 18 are not straight, the respective frames 20 should be designed and arranged so that complementary U-shaped channels 30 along the abutting edges of adjacent panel assemblies 12 are straight to facilitate interconnection via spline member 14.
The frame 20 preferably includes fastening members 34 for attaching the frame 20 to the rear face 24 of the panel 18. As illustrated in FIG. 4, the fastening member 34 can take the form of a flange 36 having a hole 38 therein through which common fasteners, such as screws, bolts or nails, may be inserted to attach the frame 20 to the panel 18. Alternate means for fastening the frame 20 to the panel 18 known to those skilled in the art, such as adhesives, hooks, or interconnecting members respectively positioned on the panel 18 and the frame 20, can be used. In order to improve the connection between the panel 18 and the frame 20, fastening members 34 can also be provided on the stabilizing track 32 so as to ensure that the center of the panel 18 does not warp or bubble after the wall is constructed.
The frame 20 may also include mounting members 40 for mounting the frame 20 to a pre-built wall frame structure. As illustrated in FIG. 4, the mounting member 40 can take the form of a hook 42 having a hole 44 therein through which common fasteners, such as screws, bolts or nails, may be inserted to attached the panel assembly 12 to a wall frame structure. Though illustrated in the form of hooks 42, the mounting members 40 can comprise any structure that enables attachment of the panel assembly to a building structure. Moreover, though the mounting members 40 are shown attached to the frame 20, the present invention also covers a panel assembly 12 wherein the mounting members 40 are attached to the rear face 24 of the panel 18.
Referring to FIG. 3, a side profile of the panel assembly 12 mounted to a wall frame structure 46 of a building is shown. The wall frame structure 46 commonly comprises a plurality of vertical studs on which a plurality of horizontal Z-bars 48, or cross members, is disposed to form a grid-like frame structure. A Z-bar is a known form of cross-member used in the art of wall construction for mounting wall panels. Typically, the Z-bar 48 has a Z-shaped cross-section and is made from galvanized sheet metal, or a metallic material of similar strength. When such a wall frame 46 is used to construct a wall structure, the inner portion of the Z-bar 48 is attached to the vertical studs. The outer portion of the Z-bar 48 extends away from the studs to engage the wall panels. Z-bars 48 are commonly positioned every two feet. In accordance with the present invention, the mounting members 40 are positioned on the frame 20 so that they catch the outer portion of the Z-bars 48 from above. Thus, hooks 42 may be positioned every vertical two feet on the frame 20, including on the stabilizing track 32 where desirable. After the panel assembly 12 is properly positioned on the horizontal Z-bars 48, selected hooks 42 may be fastened to the Z-bar 48 by common means, such as screws, through the hole 44 in the side of the hook 42 facing away from the panel 18, as seen more clearly in FIG. 4. Since the present invention allows for mounting and attachment of the panel assemblies 12 without screwing into or through the front face 22 of the panel 18, unlike in prior art wall construction methods and systems, there is no need to fill or conceal the screw holes after the panel assembly 12 is mounted to the wall frame 46. As FIG. 3 further illustrates, the present panel attachment system 10 provides for space behind each panel 18 permitting ventilation within the wall structure and therefore reducing the probability and risk of problems caused by environmental factors, such as temperature fluctuations or high humidity.
As FIG. 2 illustrates, the mounting members 40 may be positioned along track members 28 of the frame 20 in an offset manner. The offset positioning of mounting members 40 allows adjacent edges of panel assemblies to abut against adjacent edges of other panel assemblies in the wall structure, therefore eliminating the requirement of further weatherproofing, sealing or finishing steps after construction of the wall structure.
FIG. 4 provides a close-up view of a track member 28 used to construct the frame 20 of the present invention. The track member 24 has an inner surface 50 defining the channel 30 and an outer surface 52 to which fastening members 34 and mounting members 40 are attached, for example, by welding. As shown, the fastening member 34 includes the flange 36 and through hole 38, and is attached to the track member 28 on a side of the outer surface 52 that will contact the rear face 24 of the panel 18 to which the track member 28 will be attached. The mounting member 40, including hook 42, is attached to the track member 28 on a side of the outer surface 52 that will face away from the panel 18 to which the track member 28 will be attached. Preferably, hook 42 includes the through hole 44 in the side away from the panel 18 through which the hook 42 can be screwed to a Z-bar 48 after the frame 20 is properly mounted, as shown in FIG. 3. Other fastening means can be employed in accordance with the knowledge of one skilled in the art. In a preferred embodiment of the panel assembly 12, the particular track member 28 illustrated in FIG. 4 would be positioned generally horizontally proximate the lower edge of the perimeter of the rear face 24 of the panel 18.
As shown in FIG. 1, the spline member 14 is used to interconnect adjacent panel assemblies 12 a and 12 b, as well as to connect a molding piece 16 to panel assemblies 12 a and 12 b. FIGS. 5A-5E illustrate various designs of spline members, designated by reference numbers 14 a to 14 e, respectively, that can be used to interconnect and seal various portions of the wall structure. FIG. 5A illustrates the basic flat design of the spline member 14 a used in FIG. 1. Such a spline member 14 a is typically used to connect flat portions of a wall structure that are positioned adjacent one another, such as panel assemblies as shown in FIGS. 1, 9A and 9B. In such an embodiment, relatively half of the width of spline member 14 a is inserted lengthwise along preferably the entire length of an outwardly facing U-shaped channel of a first panel assembly (such as assembly 12 a), then the remaining half width of spline member 14 a is inserted into the outwardly facing U-shaped channel of the abutting edge of the adjacent second panel assembly (such as assembly 12 b) to interconnect the panel assemblies. In a preferred embodiment of the system 10, spline members 14 are made from galvanized steel with a bonded rubber seal on the outside surface, which enables a weatherproof seal between adjacent panel assemblies 12 of the wall structure, eliminating the necessity of additional weatherproofing measures such as surfacing, caulking, or cutting of expansion joints. Because such extra measures are not necessary, unlike prior art references, the only steps for wall construction with the panel attachment system 10 is mounting of the panel assemblies 12 and interconnection via spline members 14. No additional sealing or finishing steps are necessary. Further, the present invention allows the creation of wall structures at times when temperatures will reach freezing and below because a weatherproofing step is included with the interconnection step through use of the spline member 14.
As FIGS. 5B-5E further illustrate, spline members 14 may have different angles, curves or configurations in order to accommodate various wall designs, including variations in angles and curves, or provide for desired interconnections with molding pieces, detail assemblies, or any other portion of the wall structure. For example, FIG. 5B illustrates a spline member 14 b for use at right angle, corner junctions. FIG. 5C illustrates a spline member 14 c for use at T-junctions. FIG. 5D illustrates a spline member 14 d for use at Y-junctions. FIG. 5E illustrates a spline member 14 e for use at an angled junction. The possible structures of spline members that can be used in connection with the present invention are not exhausted by the designs illustrated in FIGS. 5A-5E.
FIGS. 6A-6D show various molding pieces or connection members 16 that can be used to finish edges of panel assemblies 12 (as a molding piece) or alternatively can be positioned between adjacent panel assemblies 12 for structural support or merely to improve aesthetics of the wall structure (as a connection member). As illustrated in FIG. 1, molding pieces 16 are attached to adjacent portions of the wall structure via spline members 14 inserted into generally outwardly facing U-shaped channels 54 disposed in each molding piece 16. In a preferred embodiment of the present invention, molding pieces 16 a, in the general form illustrated in FIG. 6A, may be used as moldings around the edges of a window or door in the wall structure. The molding piece 16 a is attached to the edge of a panel assembly 12 in a manner similar to the manner in which adjacent panel assemblies 12 are attached to one another—i.e., via a spline member 14 inserted into respectively facing U-shaped channels 30 or 54 of each adjacent portion of the wall structure (be it a panel assembly or a molding piece). Molding pieces 16 b and 16 c, as shown in FIGS. 6B and 6C, act as connection members between two panel assemblies 12, specifically being used in conjunction with basic flat spline members 14 a (as illustrated in FIG. 5A) to form inner or outer corners of the wall structure. Molding piece 16 d is an alternate design to the edge molding piece design of FIG. 6A, specifically illustrated a variation is the detail that may be used for the molding piece. In a preferred embodiment, molding pieces 16 can be adapted to match the finish, color, size, shape and general appearance of the panels 18 that form the wall structure. For example, for exterior application of the panel attachment system 10, the panel assemblies 12 and the molding pieces 16 may be both manufactured from Styrofoam® coated with fiber-reinforced concrete painted to the desired design for the wall.
An advantage of the panel attachment system 10 of the present invention is the ability to construct an essentially finished wall structure in a quick manner without the added time and labor for sealing adjacent wall panels. Additionally, the present invention allows for simple construction of a wall structure without exposed fasteners, such as screws, as is commonly the case with prior art methods of paneling a wall structure. In connection with this aspect of the invention, the panel assemblies 12 and molding pieces 16 of the system 10 are designed for quick mounting to a wall frame structure and quick interlocking to adjacent pieces of the panel attachment system 10, as described above, but without exposed hardware used for mounting or interlocking of the components.
For example, FIGS. 7A-7C depict the interlocking connection of longitudinally adjacent molding pieces, or connection members, in a preferred embodiment. Each molding piece 16 is equipped with at least one track 56 defining the generally outwardly facing U-shaped channel 54 into which a spline member 14 can be inserted to connect the molding piece 16 to another portion of wall structure, such as an adjacent panel assembly 12. A first longitudinal end 58 of each molding piece 16 features an outwardly jutting piece of track 56 forming a “male” connection piece 60. In this embodiment, the “male” connection piece 60 includes a screw hole 62 for connection to the inserted spline member 14. As shown, for example, in FIG. 7A, a portion of the “male” connection piece 60 on the back side of the track 56 is cut away so that the connection piece 60 is not flush with the back side of the molding piece 16. A second opposite longitudinal end 64 of the molding piece 16 features a recess forming a “female” connection piece 66 where the track 56 and the material of the molding piece 16 have been cut away, leaving a tab 68 that slides behind the “male” connection piece 60 and locks the molding piece 16 behind a longitudinally adjacent molding piece, as shown in FIGS. 7B and 7C.
The structural design of the molding piece's respective longitudinal ends 58 and 64 allows longitudinally adjacent molding pieces to be interconnected by inserting the “male” connection piece 60 into the adjacent “female” connection piece 66 along an edge of a panel assembly 12, all while concealing the respective tracks 56 and screws of each molding piece 16. The free ends of the first and last molding piece in a row are screwed or otherwise attached to the inserted spline member 14. Occasionally the screw hole will have to be caulked or otherwise concealed. FIGS. 7A and 7B illustrate the process of positioning the “female” connection piece 66 of a new molding piece onto the “male” connection end 60 of longitudinally adjacent molding piece that has already been positioned with respect to an overlapping spline member 14. The new molding piece is pivoted into position with respect to both the existing molding piece and the spline member 14. Once the new molding piece is in the position shown in FIG. 7B, it can be slid along the spline member 14 into engagement with the existing molding piece so that the “male” connection piece 60 of the existing molding piece is received in the “female” connection piece 66 of the new molding piece. The tab 68 associated with the “female” connection piece 66 aligns with the projection of the “male” connection piece 60 to provide the channel 54 at the junction to receive a spline member 14 so that both molding pieces 16 are secured into place in the wall structure. FIG. 7C shows the molding pieces interconnected after being positioned into the wall structure.
To reduce time at a job site, panel assemblies such as 12 a and 12 b in FIG. 1 are preferably pre-made and shipped to the site prior to beginning construction of a wall structure. As illustrated in FIGS. 8A and 8B, each panel to be used in the bottom course of panel assemblies is fitted with additional screw tabs, generally designated by reference numeral 70, along the bottom edge. Screw tabs 70 can later be concealed by molding pieces 16 interconnected to the bottom of applicable panel assemblies. The first panel assembly 12 mounted in place is positioned on the wall frame structure 46 on horizontal Z-bars 48 or the like using mounting members 40 attached to the frame 20, as described above with respect to FIG. 3. Once the first panel assembly 12 is properly positioned on the wall frame structure, it is attached to the Z-bars 48, for example, with screws through holes 44 in the outer surface of hooks 42, or by another means of attachment to the wall frame structure in accordance with the knowledge of one skilled in the art. Appropriately shaped spline members 14 are then inserted into the outwardly facing U-shaped channels 30 along the perimeter of the mounted panel assembly 12. Subsequent panel assemblies are positioned adjacent the mounted panel assembly and interconnected by inserting spline members 14 into respective facing U-shaped channels 30 of abutting sides of adjacent panel assemblies so that the adjacent edges of the respective panels 18 are essentially abutting, eliminating the need to treat the joints or seams. Following interconnection of abutting edges of adjacent panel assemblies, the panel assemblies are attached to the wall frame structure 46. As FIG. 8B illustrates, the offset hook arrangement used on the respective frames 20 of the panel assemblies enables each panel assembly to be attached to adjacent panel assemblies 12 on all abutting edges via spline members 14 inserted within respective facing U-shaped channels 30 without the need for additional sealing, caulking, or other concealment of holes or seams.
Furthermore, connection members or molding pieces 16 with outwardly facing U-shaped channels 54, such as those illustrated in FIGS. 6A-6D, can be attached to panel assemblies 12 using the appropriately shaped spline member 14. Molding pieces 16 having a single U-shaped channel 54, such as those shown in FIGS. 6A and 6D, are generally positioned and attached to the edges of panel assemblies 12 on the end of a wall structure or at a window or doorway via spline members 14 inserted into respective U-shaped channels 30 and 54. Connection members 16 with at least two outwardly facing U-shaped channels 54 positioned at a generally 90° angle, such as that shown in FIGS. 6B and 6C, may be used to form inner or outer corners of the wall structure. Different embodiments of such connection members or molding pieces 16 are possible, including members with various angles, curves and/or different quantities of U-shaped channels 54, depending on the specifications for the design of the wall structure.
When inserted into the outwardly facing U-shaped channels of abutting edges of wall structure components, spline members 14 generally form weatherproof seals, alleviating the requirement of further weatherproofing steps such as cutting thermal expansion joints or additional sealing treatments. The only necessary resurfacing measure required is an occasional filling of a single screw hole in the first or last portion of wall structure, which generally will be a molding component. All other screws used in assembling and constructing the wall structure are concealed by subsequently positioned panel assemblies, connection members, or molding pieces.
The foregoing description of embodiments of the invention has been presented for the purpose of illustration and description, it is not intended to be exhaustive or to limit the invention to the form disclosed. Obvious modifications and variations are possible in light of the above disclosure. The embodiments described were chosen to best illustrate the principals of the invention and practical applications thereof to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.

Claims

1. A panel attachment system for constructing a wall structure, comprising:

at least one panel assembly comprising

a panel having a perimeter, a front face and a rear face; and

a frame attached to the rear face of the panel and including a generally outwardly facing channel disposed proximate the perimeter of the panel; and

at least one spline member that is insertable into the channel of the frame to interconnect the corresponding panel assembly to an adjacent portion of the wall structure.

2. The panel attachment system according to claim 1, wherein the frame has a perimeter shape generally corresponding to the perimeter of the panel, and further wherein the channel is disposed about the perimeter shape of the frame.

3. The panel attachment system according to claim 2, wherein the panel of said panel assembly has a generally rectangular shape, said frame having a corresponding rectangular shape, and each side of said frame having a channel such that each said channel is disposed proximate a respective edge of the rectangular perimeter of the panel.

4. The panel attachment system according to claim 1, wherein the frame comprises at least one track defining the channel, said at least one track being attached to the rear face of the panel proximate the perimeter of the panel.

5. The panel attachment system according to claim 4, wherein the panel of said panel assembly has a generally rectangular shape, said frame having a corresponding rectangular shape defined by four tracks each having a channel such that each said channel is disposed proximate a respective edge of the rectangular perimeter of the panel.

6. The panel attachment system according to claim 1, wherein said at least one spline member is insertable into the channel of the frame to form a seal at the joint between the panel assembly and the adjacent portion of the wall structure to which it is interconnected.

7. The panel attachment system according to claim 1, wherein the frame further comprises a plurality of fastening members for attaching the frame to the rear face of the panel.

8. The panel attachment system according to claim 1, wherein the frame further comprises at least one mounting member for mounting the panel assembly to a wall frame in a building structure.

9. The panel attachment system according to claim 8, wherein the at least one mounting member comprises a hook.

10. The panel attachment system according to claim 1, comprising a plurality of panel assemblies that may be positioned adjacent one another to create the wall structure, each said panel assembly comprising a respective panel having a perimeter, a front face and a rear face, and a frame attached to the rear face of the corresponding panel and having a perimeter shape generally corresponding to the perimeter of the panel to which it is attached,

each said frame having a generally outwardly facing channel disposed about the perimeter shape of the frame and positioned proximate the perimeter of the corresponding panel such that the channels along abutting edges of adjacent panel assemblies face one another;

and whereby the abutting edges of adjacent panel assemblies are interconnected via a spline member placed within respective facing channels of the adjacent panel assemblies.

11. The panel attachment system according to claim 10, further comprising a connection member including at least one generally outwardly facing channel for receiving a spline member to interconnect said connection member with an adjacent panel assembly.

12. The panel attachment system according to claim 11, wherein said connection member is positionable between adjacent panel assemblies, said connection member having a generally outwardly facing channel corresponding to each adjacent panel assembly such that each channel in the connection member faces the respective generally outwardly facing channel in the adjacent panel assembly, and whereby each panel assembly is interconnected to said at least one connection member via a spline member placed within respective facing channels of the panel assemblies and the connection member.

13. The panel attachment system according to claim 11, wherein said connection member is a molding positionable at the edge of a panel assembly.

14. A panel attachment system for creating a wall structure, comprising:

a plurality of panel assemblies, each said panel assembly comprising

a panel having a perimeter, a front face and a rear face; and

a frame attached to the rear face of the panel and including a generally outwardly facing channel disposed proximate the perimeter of the panel;

wherein the channels along abutting edges of adjacent panel assemblies face one another; and

whereby adjacent panel assemblies are interconnected via a spline member placed within respective facing channels of the adjacent panel assemblies.

15. The panel attachment system according to claim 14, wherein the panel of each panel assembly has a respective perimeter shape, and the frame attached to said panel has a perimeter shape generally corresponding to the perimeter of said panel, and further wherein the channel of said frame is disposed about the perimeter shape of said frame.

16. The panel attachment system according to claim 14, further comprising a connection member including at least one generally outwardly facing channel for receiving a spline member to interconnect said connection member with at least one adjacent panel assembly.

17. A frame for mounting a panel attached thereto to a wall frame, comprising:

at least one frame member defining a perimeter of said frame generally corresponding to the perimeter of the panel attached thereto;

a plurality of fastening members for mounting the panel to the frame; and

a generally outwardly facing channel disposed in the at least one frame member about the perimeter of the frame such that the channel is positioned proximate the perimeter of the panel.

18. The frame according to claim 17, wherein frame has a generally rectangular shape defined by four frame members each having a channel.

19. The frame according to claim 17, wherein the frame further comprises at least one mounting member for mounting the frame to the wall frame.

20. The frame according to claim 17, wherein the channel is capable of receiving at least one spline member to interconnect the frame to an adjacent frame of like construction so that respective panels mounted thereto are positioned adjacent one another to define a wall.