US20200131761A1 - Wall system - Google Patents
Wall system Download PDFInfo
- Publication number
- US20200131761A1 US20200131761A1 US16/661,007 US201916661007A US2020131761A1 US 20200131761 A1 US20200131761 A1 US 20200131761A1 US 201916661007 A US201916661007 A US 201916661007A US 2020131761 A1 US2020131761 A1 US 2020131761A1
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- United States
- Prior art keywords
- wall panel
- jamb
- component
- head
- sill
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 claims abstract description 28
- 238000005253 cladding Methods 0.000 claims description 21
- 230000004888 barrier function Effects 0.000 claims description 11
- 238000009413 insulation Methods 0.000 claims description 11
- 229910001335 Galvanized steel Inorganic materials 0.000 claims description 6
- 239000008397 galvanized steel Substances 0.000 claims description 6
- 229920001296 polysiloxane Polymers 0.000 claims description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 239000004568 cement Substances 0.000 claims description 3
- 239000000835 fiber Substances 0.000 claims description 3
- 229910052751 metal Inorganic materials 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 3
- 229920002554 vinyl polymer Polymers 0.000 claims description 3
- 230000013011 mating Effects 0.000 description 16
- 238000009434 installation Methods 0.000 description 8
- 239000000463 material Substances 0.000 description 6
- 238000010276 construction Methods 0.000 description 4
- 239000012528 membrane Substances 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000000565 sealant Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 239000011521 glass Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
- E04C2/48—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose as high as or higher than the room, i.e. having provisions concerning the connection with at least two floors
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/762—Exterior insulation of exterior walls
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/88—Curtain walls
- E04B2/90—Curtain walls comprising panels directly attached to the structure
- E04B2/92—Sandwich-type panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
- E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/388—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of other materials, e.g. fibres, plastics
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
- E04C2/46—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose specially adapted for making walls
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/64—Insulation or other protection; Elements or use of specified material therefor for making damp-proof; Protection against corrosion
- E04B1/644—Damp-proof courses
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2002/001—Mechanical features of panels
- E04C2002/004—Panels with profiled edges, e.g. stepped, serrated
Definitions
- 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.
- 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 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.
- 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.
- 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.
- a wall panel in one aspect, 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.
- 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.
- 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 .
- 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
- the exterior infill component 200 also connects to the interior structural component 220 to create a wall panel 100 .
- 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 .
- 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
- FIG. 2 also illustrates the components of the interior structural component 220 .
- 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 .
- 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.
- 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 .
- 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 .
- 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 .
- 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. 9 B 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 .
- the head angle 2314 and the T-shaped head extension 3314 may be used in combination with the brake-formed sill receiver 3316 .
- 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.
- 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 .
- 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 .
- 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 .
- 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 8 C.
- 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 .
- 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 .
- the jamb receiver 1312 fits between the fourth corner 440 and the first corner 410 .
- the frame 210 design may omit the first corner 410 , second corner 420 , third corner 430 , and fourth corner 440 .
- the frame 210 may include a notched first jamb member 310 and a notched second jamb member 312 .
- 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 .
- the head member 314 and/or sill member 316 may be notched.
- 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 .
- 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.
- the frame 210 is connected to the interior structural component 220 .
- the exterior infill component 200 is also connected to the interior structural component 220 .
- 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 100 a - d.
- 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 100 a aligned adjacently with a second wall panel 100 b and a third wall panel 100 c aligned adjacently with a fourth wall panel 100 d. Additionally, the third wall panel 100 c is stacked on top of the first wall panel 100 a, and the fourth wall panel 100 d is stacked on top of the second wall panel 100 b.
- the first wall panel 100 a and the third wall panel 100 c are vertically aligned, and the second wall panel 100 b and the fourth wall panel 100 d are vertically aligned.
- FIGS. 14A-C depict alternative embodiments of the first wall panel 100 a 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 100 a including a head extension 1314 a as the head member 314 of the first wall panel 100 a and a jamb receiver 1312 a as the second jamb member 312 of the first wall panel 100 a.
- 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 100 a including a head angle 2314 a as the head member 314 of the first wall panel 100 a and a second jamb angle 2312 a as the second jamb member 312 of the first wall panel 100 a.
- the first jamb member 310 of a wall panel 100 mates with the second jamb member 312 of an adjacent wall panel 100 .
- the second jamb member 312 of the first wall panel 100 a mates with the first jamb member 310 of the second wall panel 100 b
- the second jamb member 312 of the third wall panel 100 c mates with the first jamb member 310 of the fourth wall panel 100 d.
- FIG. 15A is a front, left perspective view of a first embodiment of the top portion of a second wall panel 100 b installed with the first wall panel 100 a of FIG. 14A .
- FIG. 15A shows a jamb extension 1310 b as the first jamb member 310 of the second wall panel 100 b and a head extension 1314 b as the head member 314 of the second wall panel 100 b.
- FIG. 15A shows the jamb extension 1310 b of the second wall panel 100 b mating with the jamb receiver 1312 a of the first wall panel 100 a
- 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 2310 b as the first jamb member 310 of the second wall panel 100 b and a head angle 2314 b as the head member 314 of the second wall panel 100 b.
- FIG. 15B shows the first jamb angle 2310 b of the second wall panel 100 b mating with the second jamb angle 2312 a of the first wall panel 100 a.
- FIG. 15C is a front, left perspective view of a third embodiment of the second wall panel 100 b installed with the first wall panel 100 a of FIG. 14C .
- FIG. 15C shows a first jamb angle 2310 b as the first jamb member 310 of the second wall panel 100 b and a head angle 2314 b as a head member 314 of the second wall panel 100 b.
- the head members 314 of the first wall panel 100 a and the second wall panel 100 b also includes a T-shaped head extension 3314 .
- the T-shaped head extension 3314 may span a portion of the first wall panel 100 a and the second wall panel 100 b as shown in FIG. 15C .
- FIG. 15C shows the first jamb angle 2310 b of the second wall panel 100 b mating with the second jamb angle 2312 a of the first wall panel 100 a.
- the head member 314 of a wall panel 100 mates with the sill member 316 of a stacked wall panel 100 .
- the head member 314 of the first wall panel 100 a mates with the sill member 316 of the third wall panel 100 c
- the head member 314 of the second wall panel 100 b mates with the sill member 316 of the fourth wall panel 100 d.
- FIG. 16A depicts a third wall panel 100 c stacked on the first wall panel 100 a of FIG. 15A .
- the third wall panel 100 c includes a sill receiver 1316 c as the sill member 316 and a jamb receiver 1312 c as a second jamb member 312 .
- FIG. 16A shows the sill receiver 1316 c of the third wall panel 100 c mating with the head extension 1314 a of the first wall panel 100 a.
- FIG. 16B depicts a third wall panel 100 c stacked on the first wall panel 100 a of FIG. 15B .
- the third wall panel 100 c includes a sill angle 2316 c as the sill member 316 and a second jamb angle 2312 c as the second jamb member 312 .
- FIG. 16B shows the sill angle 2316 c of the third wall panel 100 c mating with the head angle 2314 a of the first wall panel 100 a.
- FIG. 16C depicts a third wall panel 100 c stacked on the first wall panel 100 a of FIG. 15C .
- the third wall panel 100 c includes a brake-formed sill receiver 3316 c as the sill member 316 and a second jamb angle 2312 c as the second jamb member 312 .
- FIG. 16C shows the brake-formed sill receiver 3316 c of the third wall panel 100 c mating with the combined head angle 2314 c of the first wall panel 100 a 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 100 d installed with the first wall panel 100 a, the second wall panel 100 b, and the third wall panel 100 c of FIG. 16A .
- FIG. 17A depicts a fourth wall panel 100 d adjacent to the third wall panel 100 c and stacked on the second wall panel 100 b.
- the fourth wall panel 100 d includes a jamb extension 1310 d as the first jamb member 310 and a sill receiver 1316 d as the sill member 316 .
- FIG. 17A is a front, left perspective view of a first embodiment of the bottom portion of a fourth wall panel 100 d installed with the first wall panel 100 a, the second wall panel 100 b, and the third wall panel 100 c of FIG. 16A .
- FIG. 17A depict
- 17A shows the jamb extension 1310 d of the fourth wall panel 100 d mating with the jamb receiver 1312 c of the third wall panel 100 c, and the sill receiver 1316 d of the fourth wall panel 100 d mating with the head extension 1314 b of the second wall panel 100 b.
- FIG. 17B is a front, left perspective view of a second embodiment of the fourth wall panel 100 d installed with the first wall panel 100 a, the second wall panel 100 b, and the third wall panel 100 c of FIG. 16B .
- FIG. 17B depicts a fourth wall panel 100 d adjacent to the third wall panel 100 c and stacked on the second wall panel 100 b.
- the fourth wall panel 100 d includes a first jamb angle 2310 d as the first jamb member 310 and a sill angle 2316 d as the sill member 316 .
- 17B shows the first jamb angle 2310 d of the fourth wall panel 100 d mating with the second jamb angle 2312 c of the third wall panel 100 c, and the sill angle 2316 d of the fourth wall panel 100 d mating with the head angle 2314 b of the second wall panel 100 b.
- FIG. 17C is a front, left perspective view of a third embodiment of the fourth wall panel 100 d installed with the first wall panel 100 a, the second wall panel 100 b, and the third wall panel 100 c of FIG. 16C .
- FIG. 17C depicts a fourth wall panel 100 d adjacent to the third wall panel 100 c and stacked on the second wall panel 100 b.
- the fourth wall panel 100 d includes a first jamb angle 2310 d as the first jamb member 310 and a brake-formed sill receiver 3316 d as the sill member 316 .
- FIG. 17C shows the first jamb angle 2310 d of the fourth wall panel 100 d mating with the second jamb angle 2312 c of the third wall panel 100 c, and the brake-formed sill receiver 3316 d of the fourth wall panel 100 d mating with the head angle 2314 b of the second wall panel 100 b and the T-shaped head extension 3314 (not visible in FIG. 17C ) spanning the first wall panel 100 a and the second wall panel 100 b as shown in FIGS. 15C and 16C .
- FIG. 14A-17C the wall panels 100 a - d connect together via the wall panel 100 frame 210 .
- 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.
- FIGS. 18A and 18B 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 .
- 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.
- FIGS. 19A-C 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 .
- 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 100 a - d.
- the wall panel system 600 may include seals or gaskets 506 between the head members 314 of adjacent wall panels 100 .
- 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 100 a - 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 100 a - d wall panel system 2100 can be carried out according to the method 2100 described in FIG. 21 and described below.
- step 2110 the components of a wall panel system 600 , as described above, are received.
- step 2120 the first wall panel 100 a is installed, as shown in FIGS. 14A-C , and secured to a plurality of anchors.
- the second wall panel 100 b is installed adjacent to the first wall panel 100 a, as shown in FIGS. 15A-C , by placing the first jamb member 310 of the second wall panel 100 b along the second jamb member 312 of the first wall panel 100 a.
- the second wall panel 100 b is also secured to a second plurality of anchors.
- step 2140 the third wall panel 100 c is stacked on top of the first wall panel 100 a, as shown in FIGS. 16A-C , by placing the sill member 316 of the third wall panel 100 c across the head member 314 of the first wall panel 100 a, until the third wall panel 100 c is vertically aligned with the first wall panel 100 a.
- step 2150 the fourth wall panel 100 d is stacked on top of the second wall panel 100 b, as shown in FIGS. 17A-C , by placing the first jamb member 310 of the fourth wall panel 100 d along the second jamb member 312 of the third wall panel 100 c, until the sill member 316 of the fourth wall panel 100 d meets and aligns with the head member 314 of the second wall panel 100 b. Once in position, the fourth wall panel 100 d is adjacently aligned with the third wall panel 100 c and vertically aligned with the second wall panel 100 b.
- 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 100 c.
- the T-shaped head extension 3314 is placed across the head member 314 joint of the first wall panel 100 a and the second wall panel 100 b, as shown in FIG. 15C . Then, the T-shaped head extension 3314 is connected to the head member 314 of the first wall panel 100 a and the head member 314 of the second wall panel 100 b.
- 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 100 a and the first jamb member 310 of the second wall panel 100 b, the second jamb member 312 of the third wall panel 100 c and the first jamb member 310 of the fourth wall panel 100 d, and finally, between the head member 314 of the first wall panel 100 a and the head member 314 of the second wall panel 100 b.
- Gaskets 504 may also be installed between the head member 314 of the first wall panel 100 a and the sill member 316 of the third wall panel 100 c and between the head member 314 of the second wall panel 100 b and the sill member 316 of the fourth wall panel 100 d.
- 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 100 a and the head member 314 of the second wall panel 100 b.
- the first level comprising the first wall panel 100 a and the second wall panel 100 b of each wall panel system 600
- the second level comprising the third wall panel 100 c and the fourth wall panel 100 d of each wall panel system 600
- 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.
- the wall panel system 600 is cheaper and safer to install than most wall systems.
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Abstract
Description
- This application claims the benefit of U.S. Provisional Application No. 62/749,733 for Wall System filed on Oct. 24, 2018, which is incorporated by reference as if fully set forth.
- 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.
- 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.
- 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.
- 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.
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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 fromFIG. 3 . -
FIG. 4B is a second embodiment of the cross-section view of section A-A fromFIG. 3 . -
FIG. 5A is a first embodiment of the cross-section view of section B-B fromFIG. 3 . -
FIG. 5B is a second embodiment of the cross-section view of section B-B fromFIG. 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 fromFIG. 3 . -
FIG. 7B is a second embodiment of the cross-section view of section C-C fromFIG. 3 . -
FIG. 7C is a third embodiment of the cross-section view of section C-C fromFIG. 3 . -
FIG. 8A is a first embodiment of the cross-section view of section D-D fromFIG. 3 . -
FIG. 8B is a second embodiment of the cross-section view of section D-D fromFIG. 3 . -
FIG. 8C is a third embodiment of the cross-section view of section D-D fromFIG. 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 ofFIG. 14A . -
FIG. 15B is a front, left perspective view of a second embodiment of the second wall panel installed with the first wall panel ofFIG. 14B . -
FIG. 15C is a front, left perspective view of a third embodiment of the second wall panel installed with the first wall panel ofFIG. 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 ofFIG. 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 ofFIG. 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 ofFIG. 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 ofFIG. 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 ofFIG. 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 ofFIG. 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. - 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.
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FIG. 1 is a front, right perspective view of awall panel 100. Thewall 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 thewall panel 100 shown exploded to show the components of thewall panel 100. As shown inFIG. 2 , awall panel 100 includes anexterior infill component 200, an interiorstructural component 220, and aframe 210. Theframe 210 connects to the interiorstructural component 220, and theexterior infill component 200 also connects to the interiorstructural component 220 to create awall panel 100. When thewall panel 100 is assembled, the frame protrudes out from thewall panel 100. Theframe 210 allows thewall panel 100 to connect to theframe 210 ofadjacent wall panels 100. -
FIG. 2 shows the components of theexterior infill component 200. As shown inFIG. 2 , theexterior infill component 200 may include acladding component 202, a plurality offurring strips 204, and aninsulation component 206. Theexterior infill component 200 may include only some of these components or include additional components. Thecladding component 202 may be either fiber cement cladding or metal panel cladding. However, any building code approved cladding material can be used. Thecladding component 202 is the exterior of thewall panel 100. Acladding 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 thecladding component 202 toother wall panel 100 components. Theinsulation component 206 may be any building code approved exterior continuous insulation. Theinsulation component 206 insulates the interior of a building from its surrounding environment. The components of theexterior 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 interiorstructural component 220. As shown inFIG. 2 , the interiorstructural component 220 may include aweather barrier 222, astructural sheathing component 224, and astructural frame 226. The interiorstructural component 220 may include only some of these components or include additional components. Theweather barrier 222 protects the interior components and the structure itself from moisture damage and prevents the free passage of air. Thestructural frame 226 may comprise abottom plate 228, atop plate 227, andvertical studs 229. Thestructural sheathing component 224 and thestructural frame 226 allow thewall panel 100 to be structural or load-bearing. The components of the interiorstructural component 220 are connected together via fasteners or other attachment methods such as adhesive or clips. -
FIG. 3 is a front view of theframe 210. Theframe 210 includes afirst jamb member 310, asecond jamb member 312, ahead member 314, and asill member 316.FIG. 3 illustrates the right side member of theframe 210 comprising thefirst jamb member 310, the left side of theframe 210 comprising thesecond jamb member 312, the top member of theframe 210 comprising thehead member 314, and the bottom member of theframe 210 comprising thesill member 316. However, alternative arrangements and designs are possible. -
FIG. 4A is a first embodiment of the cross-section view of section A-A fromFIG. 3 .FIG. 4A shows ajamb extension 1310 as thefirst jamb member 310.FIG. 4B is a second embodiment of the cross-section view of section A-A fromFIG. 3 .FIG. 4B shows afirst jamb angle 2310 as thefirst jamb member 310.FIGS. 4A and 4B depict exemplary designs of thefirst jamb member 310. However, other designs may be utilized for thefirst jamb member 310. -
FIG. 5A is a first embodiment of the cross-section view of section B-B fromFIG. 3 .FIG. 5A shows ajamb receiver 1312 as thesecond jamb member 312.FIG. 5B is a second embodiment of the cross-section view of section B-B fromFIG. 3 .FIG. 5B shows asecond jamb angle 2312 as thesecond jamb member 312.FIGS. 5A and 5B depict exemplary designs of thesecond jamb member 312. However, other designs may be utilized for thesecond jamb member 312. - The
first jamb angle 2310 and thesecond jamb angle 2312 may each include at least one race-way. When thewall panels 100 are installed on the project site, these race-ways are used to guide and hold seals orgaskets 502, as shown inFIG. 6B and discussed in more detail herein. -
FIG. 6A is a plan view of a first embodiment of a joinedfirst jamb member 310 and asecond jamb member 312.FIG. 6B is a plan view of a second embodiment of a joinedfirst jamb member 310 and asecond jamb member 312. As shown inFIGS. 6A and 6B , the designs of thefirst jamb member 310 and thesecond jamb member 312 correlate to allow thefirst jamb member 310 of awall panel 100 to mate with thesecond jamb member 312 of an adjacentsecond wall panel 100.FIGS. 6A and 6B show two different exemplary embodiments of afirst jamb 310 mating with asecond jamb 312.FIG. 6A shows an exemplary mating of ajamb extension 1310 andjamb receiver 1312.FIG. 6B shows an exemplary mating of afirst jamb angle 2310 andsecond jamb angle 2312. As shown inFIG. 6B , a seal orgasket 502 may be compressed between thefirst jamb angle 2310 and thesecond jamb angle 2312 to seal the joint. -
FIG. 7A is a first embodiment of the cross-section view of section C-C fromFIG. 3 .FIG. 7A shows ahead extension 1314 as thehead member 314.FIG. 7B is a second embodiment of the cross-section view of section C-C fromFIG. 3 .FIG. 7B shows ahead angle 2314 as thehead member 314.FIG. 7C is a third embodiment of the cross-section view of section C-C fromFIG. 3 .FIG. 7C shows a T-shapedhead extension 3314 as thehead member 314. The T-shapedhead extension 3314 may be used in conjunction with thehead angle 2314.FIGS. 7A, 7B, and 7C depict exemplary designs of thehead member 314. However, other designs may be utilized for thehead member 314. -
FIG. 8A is a first embodiment of the cross-section view of section D-D fromFIG. 3 .FIG. 8A shows asill receiver 1316 as thesill member 316.FIG. 8B is a second embodiment of the cross-section view of section D-D fromFIG. 3 .FIG. 8B shows asill angle 2316 as thesill member 316.FIG. 8C is a third embodiment of the cross-section view of section D-D fromFIG. 3 .FIG. 8C shows a brake-formedsill receiver 3316 as thesill member 316.FIGS. 8A, 8B, and 8C depict exemplary designs of thesill member 316. However, other designs may be utilized for thesill member 316. -
FIG. 9A is an elevation view of a first embodiment of a joinedhead member 314 and asill member 316.FIG. 9B is an elevation view of a second embodiment of a joinedhead member 314 and asill member 316.FIG. 9C is an elevation view of a third embodiment of a joinedhead member 314 and asill member 316. As shown inFIGS. 9A, 9B, and 9C , the designs of thehead member 314 and thesill member 316 correlate to allow thehead member 314 of afirst wall panel 100 to mate with thesill member 316 of a stackedsecond wall panel 100.FIG. 9A shows an exemplary joint of ahead extension 1314 and asill receiver 1316. FIG. 9B shows an exemplary joint of ahead angle 2314 and asill angle 2316.FIG. 9C shows an exemplary joint of a T-shapedhead extension 3314 and a brake-formedsill receiver 3316. As shown inFIG. 9C , thehead angle 2314 and the T-shapedhead extension 3314 may be used in combination with the brake-formedsill receiver 3316. In this embodiment, the T-shapedhead extension 3314 may run across the entire length of the top of thewall panel 100 or may run a partial length of the top of thewall panel 100. The T-shapedhead extension 3314 may be attached to thehead angle 2314 in the factory or on the project site. Thehead angle 2314, thesill angle 2316, the T-shapedhead extension 3314, and the brake-formedsill receiver 3316 may each include at least one race-way. When thewall panels 100 are installed on the project site, these race-ways may be used to guide and holdgaskets 504, as shown inFIGS. 9B and 9C . Further details of the seals orgaskets 504 are discussed below. -
FIG. 10 is a front view of afirst corner 410, asecond corner 420, athird corner 430, and afourth corner 440. Theframe 210 may include afirst corner 410, asecond corner 420, athird corner 430, and afourth corner 440. Exemplary details of thecorners FIG. 10 . Thecorners frame 210 depicted inFIG. 3 . More specifically, eachcorner first jamb member 310, thesecond jamb member 312, thehead member 314, and thesill member 316 inFIG. 3 . As shown inFIG. 10 , thefirst corner 410 comprises a notchedhead member 412 and a notchedsecond jamb member 414. Thesecond corner 420 comprises a second notchedhead member 422 and a notchedfirst jamb member 424. Thethird corner 430 comprises a second notchedfirst jamb member 434 and a notchedsill member 432. Finally, thefourth corner 440 comprises a second notchedsill member 442 and a second notchedsecond jamb member 444. Thecorners first jamb member 310, thesecond jamb member 312, thehead member 314, and thesill member 316 previously discussed and shown inFIGS. 4A, 4B, 5A, 5B, 7A, 7B, 7C, 8A, 8B , and 8C. For example, thefirst corner 410 may comprise a notchedhead extension 1314 and a notchedjamb receiver 1312; thesecond corner 420 may comprise a second notchedhead extension 1314 and a notchedjamb extension 1310; thethird corner 430 may comprise a second notchedjamb extension 1310 and a notchedsill receiver 1316; and thefourth corner 440 may comprise a second notchedsill receiver 1316 and a second notchedjamb receiver 1312. In this example, thehead extension 1314 fits between thefirst corner 410 and thesecond corner 420. Thejamb extension 1310 fits between thesecond corner 420 and thethird corner 430. Thesill receiver 1316 fits between thethird corner 430 and thefourth corner 440. Finally, thejamb receiver 1312 fits between thefourth corner 440 and thefirst corner 410. - Alternatively, the
frame 210 design may omit thefirst corner 410,second corner 420,third corner 430, andfourth corner 440. Instead, theframe 210 may include a notchedfirst jamb member 310 and a notchedsecond jamb member 312. In this embodiment, the notchedfirst jamb member 310 and the notchedsecond jamb member 312 join with thehead member 314 and/orsill member 316 at the corners of theframe 210. -
FIG. 11 is a front, left perspective view of an exemplary notchedfirst jamb angle 2310 and ahead angle 2314. Theframe 210 may include a notchedfirst jamb angle 2310 which joins with ahead angle 2314 to form a corner of theframe 210, as shown inFIG. 11 . Alternatively, thehead member 314 and/orsill member 316 may be notched. In this embodiment, the notchedhead member 314 and/or the notchedsill member 316 join with thefirst jamb member 310 and/orsecond jamb member 312 at the corners of theframe 210. - The
frame 210 may be made from aluminum, galvanized steel, vinyl, or any other rigid material having properties that meet the design needs. Theframe 210 may be non-loadbearing. The vast types of materials suitable to construct thewall panel 100 enable thewall panel 100 to be used in various types of structures. Although thewall panel 100 is depicted as rectangular in shape, thewall panel 100 and its components may be designed to conform to alternative shapes. Moreover, the materials suitable to construct thewall panel 100 can be relatively inexpensive and enable moreaffordable wall panel 100 and wall panel system designs. The components of thewall panel 100 may be prefabricated and pre-assembled in a factory, or any appropriate location. Once on site, thewall panels 100 require little or no additional components or assembly, allowing for quick andsimple wall panel 100 installation on site. -
FIG. 12 is a flow chart of a method of assembling thewall panel 1200. - In
step 1210, the components of awall panel 100, including anexterior infill component 200, an interiorstructural component 220, and aframe 210, are received. Theframe 210 includes afirst jamb member 310, asecond jamb member 312, ahead member 314, and asill member 316. The components, features, and embodiments of awall panel 100 are the same as previously described. Instep 1220, theframe 210 is connected to the interiorstructural component 220. Instep 1230, theexterior infill component 200 is also connected to the interiorstructural component 220. - More specifically, a method of assembling a
wall panel 1202 may include thestep 1212 of receiving acladding component 202, a plurality offurring strips 204, aninsulation component 206, aframe 210, aweather barrier 222, astructural sheathing component 224, and astructural frame 226. Thestructural frame 226 may comprise abottom plate 228, atop plate 227, and a plurality ofvertical studs 229.Step 1222 includes attaching thestructural sheathing component 224 to thestructural frame 226.Step 1224 includes attaching theweather barrier 222 to thestructural sheathing component 224.Step 1226 includes attaching theframe 210 to thestructural sheathing component 224.Step 1232 includes pinning theinsulation component 206 to theweather barrier 222 with the plurality of furring strips 204.Step 1234 comprises attaching the plurality offurring strips 204 to thestructural sheathing component 224.Step 1236 comprises attaching thecladding component 202 to the plurality of furring strips 204. -
FIG. 13 is a front, right perspective view of awall panel system 600, shown partially installed. Awall panel system 600 includes a plurality ofwall panels 100 connected via the wall panel frames 210. Thewall panel system 600 is shown in detail inFIGS. 13-19 .FIGS. 13-19 depict an exemplarywall panel system 600 with fourwall panels 100 a-d. However, awall panel system 600 may includeadditional wall panels 100. Eachwall panel 100 of thewall panel system 600 includes the same features, components, and embodiments of thewall panel 100 previously discussed in detail. - The
wall panel system 600 includes adjacently alignedconnected wall panels 100 as well as stackedconnected wall panels 100. The exemplarywall panel system 600 includes afirst wall panel 100 a aligned adjacently with asecond wall panel 100 b and athird wall panel 100 c aligned adjacently with afourth wall panel 100 d. Additionally, thethird wall panel 100 c is stacked on top of thefirst wall panel 100 a, and thefourth wall panel 100 d is stacked on top of thesecond wall panel 100 b. Thefirst wall panel 100 a and thethird wall panel 100 c are vertically aligned, and thesecond wall panel 100 b and thefourth wall panel 100 d are vertically aligned. -
FIGS. 14A-C depict alternative embodiments of thefirst wall panel 100 a according to the different designs of theframe 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 afirst wall panel 100 a including ahead extension 1314 a as thehead member 314 of thefirst wall panel 100 a and ajamb receiver 1312 a as thesecond jamb member 312 of thefirst wall panel 100 a. -
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 afirst wall panel 100 a including ahead angle 2314 a as thehead member 314 of thefirst wall panel 100 a and asecond jamb angle 2312 a as thesecond jamb member 312 of thefirst wall panel 100 a. - In the
wall panel system 600, thefirst jamb member 310 of awall panel 100 mates with thesecond jamb member 312 of anadjacent wall panel 100. For example, in the exemplary fourwall panel 100 a-dwall panel system 600, thesecond jamb member 312 of thefirst wall panel 100 a mates with thefirst jamb member 310 of thesecond wall panel 100 b, and thesecond jamb member 312 of thethird wall panel 100 c mates with thefirst jamb member 310 of thefourth wall panel 100 d. -
FIG. 15A is a front, left perspective view of a first embodiment of the top portion of asecond wall panel 100 b installed with thefirst wall panel 100 a ofFIG. 14A .FIG. 15A shows ajamb extension 1310 b as thefirst jamb member 310 of thesecond wall panel 100 b and ahead extension 1314 b as thehead member 314 of thesecond wall panel 100 b.FIG. 15A shows thejamb extension 1310 b of thesecond wall panel 100 b mating with thejamb receiver 1312 a of thefirst wall panel 100 a -
FIG. 15B is a front, left perspective view of a second embodiment of the second wall panel installed with the first wall panel ofFIG. 14B .FIG. 15B shows afirst jamb angle 2310 b as thefirst jamb member 310 of thesecond wall panel 100 b and ahead angle 2314 b as thehead member 314 of thesecond wall panel 100 b.FIG. 15B shows thefirst jamb angle 2310 b of thesecond wall panel 100 b mating with thesecond jamb angle 2312 a of thefirst wall panel 100 a. -
FIG. 15C is a front, left perspective view of a third embodiment of thesecond wall panel 100 b installed with thefirst wall panel 100 a ofFIG. 14C .FIG. 15C shows afirst jamb angle 2310 b as thefirst jamb member 310 of thesecond wall panel 100 b and ahead angle 2314 b as ahead member 314 of thesecond wall panel 100 b. Thehead members 314 of thefirst wall panel 100 a and thesecond wall panel 100 b also includes a T-shapedhead extension 3314. The T-shapedhead extension 3314 may span a portion of thefirst wall panel 100 a and thesecond wall panel 100 b as shown inFIG. 15C . Alternatively, there may be multiple T-shapedhead extensions 3314 wherein a first T-shapedhead extension 3314 spans thefirst wall panel 100 a and a second T-shapedhead extension 3314 spans thesecond wall panel 100 b.FIG. 15C shows thefirst jamb angle 2310 b of thesecond wall panel 100 b mating with thesecond jamb angle 2312 a of thefirst wall panel 100 a. - In the
wall panel system 600, thehead member 314 of awall panel 100 mates with thesill member 316 of astacked wall panel 100. For example, in the exemplary fourwall panel 100 a-dwall panel system 600, thehead member 314 of thefirst wall panel 100 a mates with thesill member 316 of thethird wall panel 100 c, and thehead member 314 of thesecond wall panel 100 b mates with thesill member 316 of thefourth wall panel 100 d. -
FIG. 16A depicts athird wall panel 100 c stacked on thefirst wall panel 100 a ofFIG. 15A . Thethird wall panel 100 c includes asill receiver 1316 c as thesill member 316 and ajamb receiver 1312 c as asecond jamb member 312.FIG. 16A shows thesill receiver 1316 c of thethird wall panel 100 c mating with thehead extension 1314 a of thefirst wall panel 100 a. -
FIG. 16B depicts athird wall panel 100 c stacked on thefirst wall panel 100 a ofFIG. 15B . Thethird wall panel 100 c includes asill angle 2316 c as thesill member 316 and asecond jamb angle 2312 c as thesecond jamb member 312.FIG. 16B shows thesill angle 2316 c of thethird wall panel 100 c mating with thehead angle 2314 a of thefirst wall panel 100 a. -
FIG. 16C depicts athird wall panel 100 c stacked on thefirst wall panel 100 a ofFIG. 15C . Thethird wall panel 100 c includes a brake-formedsill receiver 3316 c as thesill member 316 and asecond jamb angle 2312 c as thesecond jamb member 312.FIG. 16C shows the brake-formedsill receiver 3316 c of thethird wall panel 100 c mating with the combined head angle 2314 c of thefirst wall panel 100 a and the T-shapedhead extension 3314. -
FIGS. 17A-C correspond withFIGS. 16A-C and depict alternative embodiments according to the different designs of theframe 210 previously discussed.FIG. 17A is a front, left perspective view of a first embodiment of the bottom portion of afourth wall panel 100 d installed with thefirst wall panel 100 a, thesecond wall panel 100 b, and thethird wall panel 100 c ofFIG. 16A .FIG. 17A depicts afourth wall panel 100 d adjacent to thethird wall panel 100 c and stacked on thesecond wall panel 100 b. Thefourth wall panel 100 d includes ajamb extension 1310 d as thefirst jamb member 310 and asill receiver 1316 d as thesill member 316.FIG. 17A shows thejamb extension 1310 d of thefourth wall panel 100 d mating with thejamb receiver 1312 c of thethird wall panel 100 c, and thesill receiver 1316 d of thefourth wall panel 100 d mating with thehead extension 1314 b of thesecond wall panel 100 b. -
FIG. 17B is a front, left perspective view of a second embodiment of thefourth wall panel 100 d installed with thefirst wall panel 100 a, thesecond wall panel 100 b, and thethird wall panel 100 c ofFIG. 16B .FIG. 17B depicts afourth wall panel 100 d adjacent to thethird wall panel 100 c and stacked on thesecond wall panel 100 b. Thefourth wall panel 100 d includes afirst jamb angle 2310 d as thefirst jamb member 310 and asill angle 2316 d as thesill member 316.FIG. 17B shows thefirst jamb angle 2310 d of thefourth wall panel 100 d mating with thesecond jamb angle 2312 c of thethird wall panel 100 c, and thesill angle 2316 d of thefourth wall panel 100 d mating with thehead angle 2314 b of thesecond wall panel 100 b. -
FIG. 17C is a front, left perspective view of a third embodiment of thefourth wall panel 100 d installed with thefirst wall panel 100 a, thesecond wall panel 100 b, and thethird wall panel 100 c ofFIG. 16C .FIG. 17C depicts afourth wall panel 100 d adjacent to thethird wall panel 100 c and stacked on thesecond wall panel 100 b. Thefourth wall panel 100 d includes afirst jamb angle 2310 d as thefirst jamb member 310 and a brake-formedsill receiver 3316 d as thesill member 316.FIG. 17C shows thefirst jamb angle 2310 d of thefourth wall panel 100 d mating with thesecond jamb angle 2312 c of thethird wall panel 100 c, and the brake-formedsill receiver 3316 d of thefourth wall panel 100 d mating with thehead angle 2314 b of thesecond wall panel 100 b and the T-shaped head extension 3314 (not visible inFIG. 17C ) spanning thefirst wall panel 100 a and thesecond wall panel 100 b as shown inFIGS. 15C and 16C . - As shown in
FIG. 14A-17C , thewall panels 100 a-d connect together via thewall panel 100frame 210. Although FIGs. designated A, B, and C show three alternative embodiments, variations of theframe 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 inFIGS. 6A-6C may be paired with any head member and sill member combinations shown inFIGS. 9A-9C to form theframe 210 of thewall 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 thesecond jamb member 312 joint betweenadjacent wall panels 100 is shown inFIGS. 18A and 18B .FIG. 18A is a plan view of a first embodiment ofadjacent wall panels 100 of thewall panel system 600.FIG. 18A depicts a plan view of an exemplary joint between twoadjacent wall panels 100 in which thefirst jamb member 310 is ajamb extension 1310 and thesecond jamb member 312 is ajamb receiver 1312. -
FIG. 18B is a plan view of a second embodiment ofadjacent wall panels 100 of thewall panel system 600.FIG. 18B depicts a plan view of a second exemplary joint between twoadjacent wall panels 100 in which thefirst jamb member 310 is afirst jamb angle 2310 and thesecond jamb member 312 is asecond jamb angle 2312. - As shown in
FIGS. 18A and 18B , thewall panel system 600 may also include seals orgaskets 502. Thewall panel system 600 may include seals orgaskets 502 between thesecond jamb member 312 and thefirst jamb member 310 ofadjacent wall panels 100. The seals orgaskets 502 weatherproof thewall panel system 600 by preventing water and air from entering the joint. - A cross-section view of the
head member 314 and thesill member 316 joint between stackedwall panels 100 is shown inFIGS. 19A-C .FIG. 19A is a cross-section view of a first embodiment of stackedwall panels 100 of thewall panel system 600.FIG. 19A depicts a cross-section view of an exemplary joint between twostacked wall panels 100 in which thehead member 314 is ahead extension 1314 and thesill member 316 is asill receiver 1316. -
FIG. 19B is a cross-section view of a second embodiment of stackedwall panels 100 of thewall panel system 600.FIG. 19B depicts a cross-section view of a second exemplary joint between twostacked wall panels 100 in which thehead member 314 is ahead angle 2314 and thesill member 316 is asill angle 2316. -
FIG. 19C is a cross-section view of a third embodiment of stackedwall panels 100 of thewall panel system 600.FIG. 19C depicts a cross-section view of a third exemplary joint between twostacked wall panels 100 in which thehead member 314 is combination of ahead angle 2314 and a T-shapedhead extension 3314 and thesill member 316 is a brake-formedsill receiver 3316. - As shown in
FIGS. 19A-C , thewall panel system 600 may also include seals orgaskets 504. Thewall panel system 600 may include seals orgaskets 504 between thehead member 314 and thesill member 316 of stackedwall panels 100. The seals orgaskets 504 weatherproof thewall panel system 600 by preventing water and air from entering the joint. -
FIG. 20 is a front, left perspective view of the intersection of thewall panel system 600 showing the seals orgaskets silicone tape 508. More specifically,FIG. 20 shows the intersection of fourwall panels 100 a-d. Thewall panel system 600 may include seals orgaskets 506 between thehead members 314 ofadjacent wall panels 100. Moreover, thewall panel system 600 may includetape 508 over thehead members 314 ofadjacent wall panels 100. Thetape 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 fourwall panels 100 a-d forms a joint or intersection in the shape of a “cruciform” or “+” sign, as shown inFIG. 20 . The seals orgaskets 502, 504 (not visible inFIG. 20 ), 506 and thetape 508 weatherproof the “cruciform” or “+” sign joint of thewall panel system 600. -
FIG. 21 is a flow chart of a method of installing thewall panel system 2100. The method of installing an exemplary fourwall panel 100 a-dwall panel system 2100 can be carried out according to themethod 2100 described inFIG. 21 and described below. - In step 2110, the components of a
wall panel system 600, as described above, are received. - In
step 2120, thefirst wall panel 100 a is installed, as shown inFIGS. 14A-C , and secured to a plurality of anchors. - In
step 2130, thesecond wall panel 100 b is installed adjacent to thefirst wall panel 100 a, as shown inFIGS. 15A-C , by placing thefirst jamb member 310 of thesecond wall panel 100 b along thesecond jamb member 312 of thefirst wall panel 100 a. Thesecond wall panel 100 b is also secured to a second plurality of anchors. - In
step 2140, thethird wall panel 100 c is stacked on top of thefirst wall panel 100 a, as shown inFIGS. 16A-C , by placing thesill member 316 of thethird wall panel 100 c across thehead member 314 of thefirst wall panel 100 a, until thethird wall panel 100 c is vertically aligned with thefirst wall panel 100 a. - Finally, in
step 2150, thefourth wall panel 100 d is stacked on top of thesecond wall panel 100 b, as shown inFIGS. 17A-C , by placing thefirst jamb member 310 of thefourth wall panel 100 d along thesecond jamb member 312 of thethird wall panel 100 c, until thesill member 316 of thefourth wall panel 100 d meets and aligns with thehead member 314 of thesecond wall panel 100 b. Once in position, thefourth wall panel 100 d is adjacently aligned with thethird wall panel 100 c and vertically aligned with thesecond wall panel 100 b. - In one embodiment, the method of installing a
wall panel system 2100 may also include installing a T-shapedhead extension 3314 before installing thethird wall panel 100 c. In this embodiment, the T-shapedhead extension 3314 is placed across thehead member 314 joint of thefirst wall panel 100 a and thesecond wall panel 100 b, as shown inFIG. 15C . Then, the T-shapedhead extension 3314 is connected to thehead member 314 of thefirst wall panel 100 a and thehead member 314 of thesecond wall panel 100 b. - The method of installing a
wall panel system 2100 may further include installinggaskets second jamb member 312 of thefirst wall panel 100 a and thefirst jamb member 310 of thesecond wall panel 100 b, thesecond jamb member 312 of thethird wall panel 100 c and thefirst jamb member 310 of thefourth wall panel 100 d, and finally, between thehead member 314 of thefirst wall panel 100 a and thehead member 314 of thesecond wall panel 100 b.Gaskets 504 may also be installed between thehead member 314 of thefirst wall panel 100 a and thesill member 316 of thethird wall panel 100 c and between thehead member 314 of thesecond wall panel 100 b and thesill member 316 of thefourth wall panel 100 d. - The method of installing a
wall panel system 2100 may also comprise installingsilicone tape 508 over thehead member 314 of thefirst wall panel 100 a and thehead member 314 of thesecond wall panel 100 b. - When a plurality of
wall panel systems 600 are installed on the job site, the first level, comprising thefirst wall panel 100 a and thesecond wall panel 100 b of eachwall panel system 600, is installed around the perimeter of the structure according tosteps method 2100 described above. Then, the second level, comprising thethird wall panel 100 c and thefourth wall panel 100 d of eachwall panel system 600, is installed on top of the first level around the perimeter of the structure according tosteps steps - This method of
installation 2100 is quick and easy and requires minimal equipment. Thus, thewall 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.
Claims (36)
Priority Applications (1)
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US16/661,007 US20200131761A1 (en) | 2018-10-24 | 2019-10-23 | Wall system |
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US201862749733P | 2018-10-24 | 2018-10-24 | |
US16/661,007 US20200131761A1 (en) | 2018-10-24 | 2019-10-23 | Wall system |
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US20200131761A1 true US20200131761A1 (en) | 2020-04-30 |
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US16/661,007 Abandoned US20200131761A1 (en) | 2018-10-24 | 2019-10-23 | Wall system |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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US20220251836A1 (en) * | 2018-11-13 | 2022-08-11 | Mercer Mass Timber Llc | Cross laminated timber wall panel system |
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2019
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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US20220251836A1 (en) * | 2018-11-13 | 2022-08-11 | Mercer Mass Timber Llc | Cross laminated timber wall panel system |
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