US20230047802A1 - Polymer-based bracket system for metal panels - Google Patents
Polymer-based bracket system for metal panels Download PDFInfo
- Publication number
- US20230047802A1 US20230047802A1 US17/874,079 US202217874079A US2023047802A1 US 20230047802 A1 US20230047802 A1 US 20230047802A1 US 202217874079 A US202217874079 A US 202217874079A US 2023047802 A1 US2023047802 A1 US 2023047802A1
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- United States
- Prior art keywords
- polymeric
- insulation
- bracket member
- exterior
- section
- 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.)
- Pending
Links
- 229910052751 metal Inorganic materials 0.000 title description 32
- 239000002184 metal Substances 0.000 title description 32
- 229920000642 polymer Polymers 0.000 title description 4
- 239000000758 substrate Substances 0.000 claims abstract description 45
- 238000005253 cladding Methods 0.000 claims abstract description 22
- 238000009423 ventilation Methods 0.000 claims abstract description 13
- 239000000463 material Substances 0.000 claims description 49
- 238000009413 insulation Methods 0.000 claims description 29
- 230000014759 maintenance of location Effects 0.000 claims description 12
- 239000011810 insulating material Substances 0.000 claims description 10
- 239000000203 mixture Substances 0.000 claims description 10
- 239000011152 fibreglass Substances 0.000 claims description 8
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 8
- -1 polyxylenes Polymers 0.000 claims description 8
- 239000004793 Polystyrene Substances 0.000 claims description 6
- 239000012774 insulation material Substances 0.000 claims description 6
- 229920002223 polystyrene Polymers 0.000 claims description 6
- 229920002635 polyurethane Polymers 0.000 claims description 6
- 239000004814 polyurethane Substances 0.000 claims description 6
- 239000012783 reinforcing fiber Substances 0.000 claims description 6
- 229920001169 thermoplastic Polymers 0.000 claims description 6
- 239000004416 thermosoftening plastic Substances 0.000 claims description 6
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 4
- 229920003043 Cellulose fiber Polymers 0.000 claims description 4
- 239000004593 Epoxy Substances 0.000 claims description 4
- 239000004952 Polyamide Substances 0.000 claims description 4
- 229920000491 Polyphenylsulfone Polymers 0.000 claims description 4
- 239000004954 Polyphthalamide Substances 0.000 claims description 4
- 239000004743 Polypropylene Substances 0.000 claims description 4
- 229920006397 acrylic thermoplastic Polymers 0.000 claims description 4
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims description 4
- 125000001931 aliphatic group Chemical group 0.000 claims description 4
- 239000004760 aramid Substances 0.000 claims description 4
- 229920006231 aramid fiber Polymers 0.000 claims description 4
- 239000004917 carbon fiber Substances 0.000 claims description 4
- 229920001577 copolymer Polymers 0.000 claims description 4
- 125000003700 epoxy group Chemical group 0.000 claims description 4
- 229920001778 nylon Polymers 0.000 claims description 4
- 229920001568 phenolic resin Polymers 0.000 claims description 4
- 239000005011 phenolic resin Substances 0.000 claims description 4
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims description 4
- 229920002647 polyamide Polymers 0.000 claims description 4
- 239000004417 polycarbonate Substances 0.000 claims description 4
- 229920000515 polycarbonate Polymers 0.000 claims description 4
- 229920000647 polyepoxide Polymers 0.000 claims description 4
- 229920000728 polyester Polymers 0.000 claims description 4
- 229920006393 polyether sulfone Polymers 0.000 claims description 4
- 229920001470 polyketone Polymers 0.000 claims description 4
- 229920006375 polyphtalamide Polymers 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 229920005989 resin Polymers 0.000 claims description 4
- 239000011347 resin Substances 0.000 claims description 4
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 claims description 4
- 239000004634 thermosetting polymer Substances 0.000 claims description 4
- 229920001567 vinyl ester resin Polymers 0.000 claims description 4
- 239000006260 foam Substances 0.000 claims description 3
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- 239000001913 cellulose Substances 0.000 claims description 2
- 238000009472 formulation Methods 0.000 claims description 2
- 239000011490 mineral wool Substances 0.000 claims description 2
- 229920000582 polyisocyanurate Polymers 0.000 claims description 2
- 239000011495 polyisocyanurate Substances 0.000 claims description 2
- 239000011493 spray foam Substances 0.000 claims description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 5
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- 229910052742 iron Inorganic materials 0.000 description 3
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- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
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- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
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- 239000003063 flame retardant Substances 0.000 description 1
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- 238000001746 injection moulding Methods 0.000 description 1
- 239000002917 insecticide Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
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- 235000015112 vegetable and seed oil Nutrition 0.000 description 1
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- 229910052725 zinc Inorganic materials 0.000 description 1
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0801—Separate fastening elements
- E04F13/0803—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
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- E—FIXED CONSTRUCTIONS
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- 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
- E04B1/38—Connections for building structures in general
- E04B1/388—Separate connecting elements
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- E04B1/40—
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- E—FIXED CONSTRUCTIONS
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- 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
- E04B1/7645—Exterior insulation of exterior walls with ventilation means for the insulation
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- 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
- E04B1/7654—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 comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/007—Outer coverings for walls with ventilating means
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0801—Separate fastening elements
- E04F13/0803—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
- E04F13/081—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements
- E04F13/0816—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements extending into the back side of the covering elements
- E04F13/0817—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements extending into the back side of the covering elements extending completely through the covering elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/12—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of metal or with an outer layer of metal or enameled metal
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/21—Fastening means specially adapted for covering or lining elements
- E04F13/22—Anchors, support angles or consoles
-
- 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
- E04B1/38—Connections for building structures in general
- E04B1/388—Separate connecting elements
- E04B2001/389—Brackets
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- E04B2001/405—
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- 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
- E04B2001/7679—Means preventing cold bridging at the junction of an exterior wall with an interior wall or a floor
Definitions
- metal materials typically an exterior and interior metal skin
- metal materials typically an exterior and interior metal skin
- These metal skins are typically profiled and have offsets in them to prevent the exterior metal skin from contacting the interior metal skin. This is done in an effort to prevent metal to metal contact thereby reducing thermal conductivity from the outside of the building.
- Heat travels in the path of least resistance such that heat can invade a system and affect an interior atmosphere through relatively finite pathways such as fasteners and the like that have metal to metal contact with exterior conditions.
- metal roof and wall assemblies retain at least some form of metal to metal contact through metal anchors, fasteners, or sill, transition, and window trim.
- Products of this type are subject to shorter warrantees and life cycles due to the fact that the product is glued or otherwise bonded and is subject to damage and shortened life spans from thermal cycling which causes varying rates of contraction and expansion of the different materials and therefore wears significantly on any given system.
- these systems often require like materials to be in contact with each other which can lead to reactions such as oxidation which can corrode these materials over time.
- a metal wall, roof or deck system that creates a thermal break in the heat conductivity path thereby effectively eliminating or greatly reducing thermal bridging from exterior conditions to interior conditions that keeps like materials separate is desired.
- the present invention is a system for supporting exterior cladding units on a substrate of a structure.
- the system includes a polymeric bracket system made up of a plurality of polymeric bracket members, and each of the bracket members have at least one anchor section, at least one web section and at least one support section.
- the anchor section(s) attaches the bracket member to the substrate, the web section(s) connects the anchor section(s) to the support section(s), and the support section(s) attaches to the exterior cladding unit.
- the polymeric bracket members provide a thermal break from the exterior cladding unit to the substrate of the building structure.
- each of the polymeric bracket members are mounted to the building structure to form rows thereby forming channels between the exterior cladding units and the substrate when the exterior cladding units are mounted.
- a ventilation system having a plurality of vents is formed by the mounting of the exterior cladding units to the polymeric bracket system.
- Another aspect of the present invention is a polymeric bracket member having at least one anchor section, at least one support section, and at least one web section.
- the anchor section has at least one channel.
- the support section also has at least one channel. The channel(s) of the support section is adapted to retain an insert.
- Bracketing system having a grooved polymeric stud.
- the system also includes first and second clips operably coupled to the stud.
- the first and second clips have attachment surfaces and comprise channels.
- FIG. 1 is a perspective view of a building having a wall system embodying the present invention
- FIG. 2 is a perspective view of a bracket system and exterior panel
- FIG. 2 A is a perspective view of a bracket system and exterior panel
- FIG. 3 is a perspective view of a bracket system and exterior panel attached to a building substrate
- FIG. 3 A is a fragmentary perspective view of a bracket system and exterior panel attached to a building substrate
- FIG. 4 is a fragmentary elevational view of a bracket member and exterior panel attached to a substrate
- FIG. 5 is a side elevational view of a bracket member
- FIG. 5 A is a side elevational view of a bracket member
- FIG. 6 is a fragmentary perspective view of a bracket member
- FIG. 7 is a fragmentary perspective view of a bracket member
- FIG. 8 is a perspective view of a bracket system and exterior panel of another embodiment of the present invention.
- FIG. 8 A is a fragmentary perspective view of a bracket system
- FIG. 9 is a side elevational view of a bracket system
- FIG. 10 is a fragmentary elevational view of a bracket system attached to a building substrate and exterior panel
- FIG. 11 is a perspective view of a bracket system and exterior panel
- FIG. 12 is a perspective view of a bracket system attached to a building substrate and exterior panel
- FIG. 12 A is a fragmentary perspective view of a bracket system attached to a building substrate and exterior panel;
- FIG. 13 is a side elevational view of a bracket system of another embodiment of the present invention.
- FIG. 13 A is a fragmentary side elevational view of a bracket system attached to a substrate and exterior panel;
- FIG. 14 is a fragmentary perspective view of a bracket member
- FIG. 15 is a fragmentary perspective view of a bracket member.
- the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1 .
- the invention may assume various alternative orientations, except where expressly specified to the contrary.
- the specific devices and processes illustrated in the attached drawings, and described in following specification are simply exemplary embodiments. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be construed as limiting, unless expressly stated otherwise.
- the reference numeral 2 ( FIG. 1 ) generally designates one embodiment of the present invention wherein a building structure includes a roof 4 with sides 5 , 6 , a front wall 8 , and a side wall 10 .
- the side wall or building substrate 10 is covered by exterior cladding units 12 which, in this embodiment, are depicted as ribbed panels made of a substrate generally known in the industry for use in an exterior surface of a building structure 2 such as steel, aluminum, zinc, and other such substrates.
- the front wall 8 is shown with a polymeric bracket system having rows 14 made up of polymeric bracket members or girts 16 which exhibit low thermal conductivity and are used to connect the exterior cladding units 12 to the building structure 2 .
- insulating material 18 is housed in the channels disposed between the rows 14 of bracket members 16 , wherein the insulating material 18 , as shown in this embodiment, are modular insulation panels that serve to insulate the building structure 2 in assembly.
- the insulating material 18 can also be fire retardant panels, sound dampening panels or any other type of insulating material or panel known in the art for providing an interior or exterior wall with a quality for which the panel is known.
- Other such insulating materials or panels include materials having additives like insecticides, fungicides or colorants for example.
- insulating materials 18 are exemplified as panels designed to insulate the building structure.
- Other insulating materials suitable for use with the present invention include, foam, fiberglass insulation, rigid insulation, semi rigid insulation, blanket insulation, loose fill insulation, spray foam in either fiberglass, rock wool, cellulose based, polystyrene, polyisocyanurate, polyurethane or other polymeric insulation formulation.
- the exterior cladding units 12 are exemplified as modular exterior panels made of a metal substrate.
- the present invention is for use in many different applications such as wall systems, roof systems, decking systems and the like.
- an embodiment of the present invention will be exemplified as a metal wall panel system for description purposes, but is no way designed to limit the scope of the invention to an exterior wall panel system.
- fasteners 20 as known in the art are used to connect bracket members 16 to a building substrate such as the front wall 8 of the building structure 2 .
- fasteners 22 are used to connect the panels 12 to the bracket member 16 as indicated by the dotted lines in assembly thereby rigidly connecting the panels 12 to the substrate or front wall 8 of the building structure 2 .
- insulating panels 18 are disposed between the bracket members 16 in the channels formed between rows 14 .
- an exterior panel 12 is secured to the bracket member 16 by fasteners 22 and the bracket member 16 are further coupled to the front wall 8 of the building structure 2 by fasteners 20 .
- the bracket members 16 further comprise retention pins 24 , or panel retention pins, in this embodiment, which are used to hold insulation panels 18 in place during assembly.
- the bracket member 16 is shown operably coupled to a substrate 8 and operably coupled to an exterior panel 12 in a lateral relationship, and has insulation panels 18 vertically disposed on either side of the bracket member 16 .
- the bracket member 16 having low thermal conductivity, creates a thermal break in the path of heat conductivity from the exterior panel 12 to the building substrate 8 in such a way that there is no metal to metal contact.
- the term “thermal break” refers to a break in like materials wherein the material disposed between like materials is comprised of a material having low thermal conductivity such as a polymeric material having a high R-value as further described below.
- R-values are measurements of the thermal resistance of different materials. R-values are well known by those skilled in the art of the construction and insulation industries. Further, in this configuration, there are no like materials in contact with another, nor is there any metal to metal contact creating a pathway for heat to transfer from the exterior to the interior and vice versa.
- a ventilation system is comprised in part by vents 26 and 28 disposed above and below the bracket member 16 such that vents 26 are formed between the insulation panel 18 and the exterior panel 12 and vents 28 are formed between the insulation panel 18 and the building substrate 8 .
- FIG. 5 generally depicts a side elevational view of a bracket member 16 which, in this embodiment, has a general Z-shaped configuration with a support section 32 , adapted to connect to and support an exterior cladding unit.
- the support section 32 of the bracket member 16 includes an exterior surface 34 and interior surface 36 wherein the interior surface 36 further comprises a T-shaped channel 38 .
- the support section 32 has a planar thickness “A” which correlates to the size of the vents 26 which are disposed between the insulation panels 18 and the exterior panels 12 , as shown in FIG. 4 .
- the bracket member 16 further comprises a web or body section 40 which has a first side 42 and a second side 44 wherein an aperture 49 is disposed on the body section 40 of the bracket member 16 and is configured to house pins 24 which help to hold the insulation panels 18 in place in assembly.
- the web or body section 40 connects the support section 32 to the anchor section 48 described below.
- the aperture 49 further comprises a beveled side 56 disposed on the second side 44 of the body section 40 of the bracket member 16 .
- the beveled section 56 of aperture 49 can be disposed on the first side 42 , the second side 44 , or both the first and second sides 42 , 44 of the body section 40 of the bracket member 16 for positively capturing a pin 24 (not shown) with a beveled head that corresponds to the counter sunk beveled edge or edges of aperture 49 .
- the body portion 40 further comprises retention fins or panel piercing airlock ribs 46 which, in this embodiment help to hold insulation panels 18 in place.
- the insulation panels 18 (not shown) can be manufactured with a channel that corresponds to the fins or ribs 46 of the bracket member 16 to retain the insulation panels 18 in place in assembly.
- the body section 40 of the bracket member 16 has a length “C” which generally corresponds to the width of the insulation panels 18 .
- the bracket member 16 further comprises an anchor section 48 having an exterior side 50 and an interior side 52 which is used to anchor the bracket member 16 to a substrate 8 with fasteners 20 such as shown in FIG. 4 .
- the anchor section 48 of the bracket member 16 has a planar thickness “B” which corresponds to the width of the vents 28 as shown in FIG. 4 in a similar fashion as vents 26 correspond to planar thickness “A” of the support section 32 .
- the bracket member 16 further comprises channels 58 disposed on both the support section 32 and anchor section 48 which are used to guide fasteners 20 and 22 in assembly.
- the support section 32 of the bracket member 16 further comprises a T-shaped channel 38 which is adapted to accept an insert (not shown) which is used to help retain fasteners in assembly as described in more detail below.
- a bracket member 30 generally has similar features as the bracket shown in FIG. 5 with exception of the exterior side 50 of the anchor section 48 having a T-shaped channel 54 for use in accepting an insert (not shown) which is used to help retain fasteners 20 in assembly.
- the bracket member 16 further comprises a slideable, insert 60 which can be inserted into T-shaped channel 38 and moved laterally along T-shaped channel 38 by sliding the insert 60 along the length of the T-shaped channel 38 to facilitate fastener retention when fasteners 22 (not shown) are used to secure exterior panels 12 to the bracket member 16 .
- the insert 60 can be an insert which can be made of a rigid polymer, metal or other like reinforcing material adapted to rigidity the bracket members 16 and retain fasteners in assembly.
- the insert 60 can also be made from recycled materials such as recycled metal or other like material.
- the T-shaped channel 38 disposed on the interior surface 36 of support section 32 further comprises channel tabs 39 which positively capture the insert 60 in the T-shaped channel 38 while allowing the insert to slide along the length of the T-shaped channel 38 .
- the anchor section 48 of the bracket member 16 further comprises channels 62 disposed along the interior side 52 of the anchor section 48 wherein the channels 62 vertically span the length of the interior side 52 of the anchor section 48 .
- the channels 62 make up, in part, the ventilation system of this embodiment by providing a cross ventilation air groove for rear ventilating and rain screening of the bracket and panel system.
- the bracket members 16 are developed from an anticorrosive polymeric material that exhibits high insulative qualities or rather, demonstrates high R-value properties such as an R-value in the range of about R1.5 to about R8 per inch.
- Polymeric materials suitable for the present invention include thermoplastics or thermoset resin materials including for example: acrylonitrile-butadiene-styrene (ABS) copolymers, vinylesters epoxies, phenolic resins, polyvinyl chlorides (PVC), polyesters, polyurethanes, polyphenylsufone resin, polyarylsulfones, polyphthalimide, polyamides, aliphatic polyketones, acrylics, polyxylenes, polypropylenes, polycarbonates, polyphthalamides, polystyrenes, polyphenylsulfones, polyethersulfones, polyfluorocarbons and blends thereof.
- ABS acrylonitrile-butadiene-styrene
- thermoplastics and thermoplastic resins suitable for the present invention are known in the art which demonstrate high R-values and are thereby heat resistant as well as anticorrosive.
- Thermoplastics of the present invention are also contemplated using a recyclable polymer or are made of a polymeric material which is partially comprised of a renewable resource such as vegetable oil or the like in its composition when an eco-friendly or “green” bracket member is desired.
- the polymeric material of the present invention can also be reinforced with a reinforcing fiber as detailed below.
- Bracket members composed of the materials discussed above form a thermal break between exterior panels and building substrates in an effort to control the temperature within a building structure by reducing or eliminating thermal conductivity from the exterior panel to the building substrate and vice versa.
- the U-value of an exterior wall panel system of the present invention can typically exhibit a U-value from about U1.5 to about U30 depending on the thickness of the overall system, the insulation materials used and the composition of the bracket members.
- a material’s K-value relates to a specific material’s thermal conductivity
- a material’s C-value correlates to the material’s thermal conductance
- a material’s R-value relates to a material’s thermal resistance
- a U-value relates to the thermal transmittance of an overall system.
- materials with low K-values and C-values are desired while materials with high R-values are desired.
- the overall thermal transmittance, or U-value, of the system is low.
- the U-value the lower the rate heat thermally bridges from one material to another.
- a building structure having a well insulated system will have a much lower U-value than an uninsulated or poorly insulated system exhibiting high thermal transmittance.
- R-value of the bracket members of the present invention a relatively high R-value is desired to ensure adequate insulation of a building structure from outside elements by making a bracket that creates thermal break in a wall panel system.
- a range of R-values for the polymeric materials used to construct the bracket members described above would be a range of about R1.5 to about R8 per inch in order to create a thermal break that effectively reduces or eliminates thermal bridging.
- the thermal conductivity, or K-value is the reciprocal of the material’s R-value, such that for a polymeric material exhibiting an R-value of about R1.5 to R8 per inch, the correlating K-value for that material would be from about K0.66 to about K0.125 per inch.
- a polymeric bracket member of the present invention will exhibit a K-value of approximately about K.5 to about K0.125per inch at a given set of conditions as compared to a bracket made from a material such as iron or steel which would have an approximate K-value as high as K32 to K60 per inch at the same conditions. This is because iron and steel have low R-values and are well known conductors of heat.
- the bracket members of the present invention are typically molded members which are formed from the materials noted above and generally used in an molding processes such as injection molding, extrusion molding, pultrusion molding and other such molding techniques known in the art.
- a reinforcing fiber may be introduced into the polymeric mix to increase the strength of the polymeric bracket member.
- glass fibers fiberglass
- carbon fibers cellulose fibers
- nylon fibers aramid fibers
- other such reinforcing fibers can be introduced into the overall polymeric composition before or during the molding process, thereby resulting in a bracket member which has a sufficiently high R-value to create a thermal break in a metal wall system of a building structure, while also having the requisite strength to adequately support exterior panels of a metal panel wall system on a building substrate.
- dotted lines indicate the mounting of an exterior cladding unit 70 , shown in FIG. 8 as an exterior panel, to a building structure 72 .
- the building structure has walls 74 , 76 which can be any substrate normally found on a building structure such as a sheathed stud wall, a concrete wall, a masonry wall, or a steel roof deck.
- the exterior panel 70 attaches to the building structure via a bracketing system 80 ( FIG. 8 A ) which comprises a grooved stud 82 generally made of a polymeric material having a significantly high R-value (as described above for bracket member 16 ) and clips 84 , 86 which are generally made of a metallic material.
- a bracketing system 80 FIG. 8 A
- the stud 82 has a first end 88 and a second end 89 which further comprise channels 92 giving the first end 88 and second end 89 a general T-shaped configuration.
- Channels 92 are U-shaped channels disposed on first and second sides 90 and 91 of the grooved stud 82 .
- Clips 84 and 86 comprise flanges 94 which coordinate to form a T-shaped channel 96 which generally correlates to the T-shaped first and second ends 88 and 89 of the stud 82 .
- the clips 84 and 86 further comprise U-shaped channels 98 which correlate with U-shaped channels 92 of the grooved stud 82 .
- the configuration of the stud 82 and the clips 84 and 86 coincide such that the clips 86 and 84 can slide on to the ends 88 and 89 of the stud 82 as shown in FIG. 9 .
- the clips 84 and 86 further comprise attachment surfaces 100 which are used to attach the clips to either a building substrate or an exterior panel.
- the stud 82 further comprises retention fins, or in this embodiment, panel retention fins 102 used to keep insulating materials, such as panels 104 , in place in assembly as shown in FIG. 10 .
- the panel retention fins 102 are disposed on both first and second sides 90 , 91 of the stud 82 . As shown in FIG.
- a plurality of bracketing systems 80 are attached to a building structure 72 on the building structures exterior walls 74 or 76 .
- the bracketing systems 80 are attached to the wall 76 as shown in FIG. 11 , in a vertical stud-like fashion.
- clip 84 is attached to the building structure substrate or wall 76 at the attachment surface 100 of the clip 84 .
- the stud 82 is then disposed between clip 84 and clip 86 and the clips are attached to stud 82 in the manner shown in FIG. 9 such that attachment surface 100 of clip 86 is exposed for the attaching of an exterior panel 70 .
- the exterior panel 70 is attached to a plurality of bracketing systems 80 by fasteners 106 .
- a panel 104 is disposed wherein the panel 104 is made of a material similar to the panels 12 as described above.
- the stud 82 creates a thermal break between the exterior panel 70 and the building substrate 76 .
- a bracketing system 80 is shown attached to a substrate 76 via a clip 84 through fasteners (not shown) and further attached to an exterior panel 70 via clip 86 using fasteners 106 .
- the panel retention fins 102 are shown fitting into grooved channels 108 formed in the panel 104 to help align the panel 104 in assembly.
- a ventilation system includes vents 110 and 112 , which correlate to the thickness of attachment surfaces 100 of clips 84 and 86 , wherein the vent 110 is disposed between panel 104 and the substrate 76 and vent 112 is disposed between panel 104 and exterior panel 70 .
- a polymeric bracket member 114 is shown as a hat-shaped bracket member, or girt ( FIG. 13 ).
- the bracket member 114 comprises first and second bottom anchor flanges or sections 116 and 118 having exterior sides 120 and 122 respectively, and interior sides 124 and 126 respectively.
- T-shaped channels 128 are disposed on the interior sides 124 , 126 of anchor flanges 116 , 118 , and the T-shaped channels 128 have channel tabs 129 which are used to positively capture an insert 130 in assembly.
- Fastener guide channels 132 are disposed on the exterior and interior sides 120 , 122 , 124 , 126 of the bottom anchor flanges 116 , 118 for use in guiding fasteners through a bracket member into a substrate.
- the bracket member 114 further comprises first and second webs or side walls 134 , 136 which have insulation panel retention fins 138 disposed on either side of side walls 134 , 136 to facilitate the retention of insulation panels in assembly.
- the bracket member 114 further comprises a top support section 140 which has an exterior side 142 and an interior side 144 . Both the exterior side and the interior side have fastener guide channels 132 and the interior side 144 further comprises a T-shaped channel 146 having tabs 148 for positively capturing a variable gauge insert (not shown) in assembly.
- bracket member 114 is shown in a wall assembly wherein the bracket member 114 is attached to a building substrate 154 at bottom anchor flanges 116 , 118 . This attachment is made by fasteners known in the art (not shown). Panels 150 and 152 are shown in the assembly wherein panels 150 span between bracket member 114 and another like bracket member 114 (not shown). Panel 152 is disposed in a channel formed between side walls 134 and 136 of bracket member 114 . An exterior panel 156 is attached to top support section 140 of bracket member 114 via fasteners 158 .
- a ventilation system further includes vents 160 , which are formed between panels 150 and exterior panels 156 , for ventilation and rain sheeting of the system.
- Vents 164 are formed between the panels 150 and the building substrate 154 for cross-ventilation and moisture sheeting purposes and vent 162 is formed between panel 152 and the building substrate 154 for ventilation within the interior space of bracket member 114 .
- bracket member 114 formed from a polymeric material having a high R-value, forms a thermal break between the exterior panel 156 and the building substrate 154 . Further, in this configuration, there are no like materials in contact with another, nor is there any metal to metal contact creating a pathway for heat to transfer from the exterior to the interior and vice versa.
- the bracket member 114 is shown with inserts 160 to be inserted in the T-shaped channels 128 disposed on the interior sides 124 , 126 of the bottom anchor flanges 116 , 118 where they will be held in place by channel tabs 129 .
- the inserts 160 are made of a rigid material, such as a rigid polymer or metallic material and are slideable along the length of the T-shaped channels 128 . Further, it is contemplated that a similar insert (not shown) can be inserted in the T-shaped channel 146 disposed on the interior side 144 of the top support 140 of bracket member 114 .
- the top support 140 has channel tabs 148 disposed on the interior side 146 of the top support 140 , which hold an insert (not shown) in place in assembly.
- An insert used in the T-shaped channel 146 is slideable along the length of the channel 146 to a desired location where fasteners (not shown) will be used to hold an exterior panel (not shown) in place on top support 140 .
- the inserts 160 as well as the insert used in T-shaped channel 146 , are used to retain the fasteners in place in assembly.
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Abstract
A system for supporting exterior panels on a substrate of a building structure. The system has a plurality of polymeric bracket members, and each of the bracket members have at least one anchor section, at least one web section and at least one support section. The polymeric bracket members provide a thermal break from the exterior panel to the substrate of the building structure. A plurality of exterior cladding units are held in place by the bracket members. A plurality of vents are disposed between the panels and the exterior panels, and a plurality of vents are also disposed between the panels and the substrate, thereby forming a ventilation system.
Description
- In the past, in order to provide a highly thermally efficient (metal) wall or (metal) roof assembly for a building enclosure, it has been necessary for metal materials, typically an exterior and interior metal skin, to be bonded to either side of an insulated panel core inside a factory thereby creating a foam panel. These metal skins are typically profiled and have offsets in them to prevent the exterior metal skin from contacting the interior metal skin. This is done in an effort to prevent metal to metal contact thereby reducing thermal conductivity from the outside of the building. Heat travels in the path of least resistance such that heat can invade a system and affect an interior atmosphere through relatively finite pathways such as fasteners and the like that have metal to metal contact with exterior conditions. Most applications of metal roof and wall assemblies retain at least some form of metal to metal contact through metal anchors, fasteners, or sill, transition, and window trim. Products of this type are subject to shorter warrantees and life cycles due to the fact that the product is glued or otherwise bonded and is subject to damage and shortened life spans from thermal cycling which causes varying rates of contraction and expansion of the different materials and therefore wears significantly on any given system. Furthermore, these systems often require like materials to be in contact with each other which can lead to reactions such as oxidation which can corrode these materials over time. A metal wall, roof or deck system that creates a thermal break in the heat conductivity path thereby effectively eliminating or greatly reducing thermal bridging from exterior conditions to interior conditions that keeps like materials separate is desired.
- One aspect of the present invention is a system for supporting exterior cladding units on a substrate of a structure. The system includes a polymeric bracket system made up of a plurality of polymeric bracket members, and each of the bracket members have at least one anchor section, at least one web section and at least one support section. The anchor section(s) attaches the bracket member to the substrate, the web section(s) connects the anchor section(s) to the support section(s), and the support section(s) attaches to the exterior cladding unit. The polymeric bracket members provide a thermal break from the exterior cladding unit to the substrate of the building structure. In the polymeric bracket system, each of the polymeric bracket members are mounted to the building structure to form rows thereby forming channels between the exterior cladding units and the substrate when the exterior cladding units are mounted. A ventilation system having a plurality of vents is formed by the mounting of the exterior cladding units to the polymeric bracket system.
- Another aspect of the present invention is a polymeric bracket member having at least one anchor section, at least one support section, and at least one web section. The anchor section has at least one channel. The support section also has at least one channel. The channel(s) of the support section is adapted to retain an insert.
- Yet another aspect of the present invention is a bracketing system having a grooved polymeric stud. The system also includes first and second clips operably coupled to the stud. The first and second clips have attachment surfaces and comprise channels.
- These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
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FIG. 1 is a perspective view of a building having a wall system embodying the present invention; -
FIG. 2 is a perspective view of a bracket system and exterior panel; -
FIG. 2A is a perspective view of a bracket system and exterior panel; -
FIG. 3 is a perspective view of a bracket system and exterior panel attached to a building substrate; -
FIG. 3A is a fragmentary perspective view of a bracket system and exterior panel attached to a building substrate; -
FIG. 4 is a fragmentary elevational view of a bracket member and exterior panel attached to a substrate; -
FIG. 5 is a side elevational view of a bracket member; -
FIG. 5A is a side elevational view of a bracket member; -
FIG. 6 is a fragmentary perspective view of a bracket member; -
FIG. 7 is a fragmentary perspective view of a bracket member; -
FIG. 8 is a perspective view of a bracket system and exterior panel of another embodiment of the present invention; -
FIG. 8A is a fragmentary perspective view of a bracket system; -
FIG. 9 is a side elevational view of a bracket system; -
FIG. 10 is a fragmentary elevational view of a bracket system attached to a building substrate and exterior panel; -
FIG. 11 is a perspective view of a bracket system and exterior panel; -
FIG. 12 is a perspective view of a bracket system attached to a building substrate and exterior panel; -
FIG. 12A is a fragmentary perspective view of a bracket system attached to a building substrate and exterior panel; -
FIG. 13 is a side elevational view of a bracket system of another embodiment of the present invention; -
FIG. 13A is a fragmentary side elevational view of a bracket system attached to a substrate and exterior panel; -
FIG. 14 is a fragmentary perspective view of a bracket member; and -
FIG. 15 is a fragmentary perspective view of a bracket member. - For the purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in following specification, are simply exemplary embodiments. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be construed as limiting, unless expressly stated otherwise. - The reference numeral 2 (
FIG. 1 ) generally designates one embodiment of the present invention wherein a building structure includes a roof 4 withsides front wall 8, and aside wall 10. The side wall orbuilding substrate 10 is covered byexterior cladding units 12 which, in this embodiment, are depicted as ribbed panels made of a substrate generally known in the industry for use in an exterior surface of abuilding structure 2 such as steel, aluminum, zinc, and other such substrates. Thefront wall 8 is shown with a polymeric bracketsystem having rows 14 made up of polymeric bracket members orgirts 16 which exhibit low thermal conductivity and are used to connect theexterior cladding units 12 to thebuilding structure 2. Disposed betweenrows 14, are channels that are formed between thebuilding substrate 10 and theexterior cladding units 12 when theexterior cladding units 12 are mounted to thebracket members 16. As shown in the embodiment inFIG. 1 ,insulating material 18 is housed in the channels disposed between therows 14 ofbracket members 16, wherein theinsulating material 18, as shown in this embodiment, are modular insulation panels that serve to insulate thebuilding structure 2 in assembly. The insulatingmaterial 18 can also be fire retardant panels, sound dampening panels or any other type of insulating material or panel known in the art for providing an interior or exterior wall with a quality for which the panel is known. Other such insulating materials or panels include materials having additives like insecticides, fungicides or colorants for example. Though many types of insulating materials are known in the art, for the purposes of the description below, insulatingmaterials 18, as depicted in the accompanying figures, are exemplified as panels designed to insulate the building structure. Other insulating materials suitable for use with the present invention include, foam, fiberglass insulation, rigid insulation, semi rigid insulation, blanket insulation, loose fill insulation, spray foam in either fiberglass, rock wool, cellulose based, polystyrene, polyisocyanurate, polyurethane or other polymeric insulation formulation. Further, for the purposes of the description below, theexterior cladding units 12, as depicted in the figures, are exemplified as modular exterior panels made of a metal substrate. The present invention is for use in many different applications such as wall systems, roof systems, decking systems and the like. For purposes of this application, an embodiment of the present invention will be exemplified as a metal wall panel system for description purposes, but is no way designed to limit the scope of the invention to an exterior wall panel system. - As shown in
FIG. 2 ,fasteners 20 as known in the art are used to connectbracket members 16 to a building substrate such as thefront wall 8 of thebuilding structure 2. As shown inFIG. 2A ,fasteners 22 are used to connect thepanels 12 to thebracket member 16 as indicated by the dotted lines in assembly thereby rigidly connecting thepanels 12 to the substrate orfront wall 8 of thebuilding structure 2. As shown inFIG. 2 , insulatingpanels 18 are disposed between thebracket members 16 in the channels formed betweenrows 14. - As shown in
FIG. 3 , anexterior panel 12 is secured to thebracket member 16 byfasteners 22 and thebracket member 16 are further coupled to thefront wall 8 of thebuilding structure 2 byfasteners 20. As shown inFIG. 3A , thebracket members 16 further comprise retention pins 24, or panel retention pins, in this embodiment, which are used to holdinsulation panels 18 in place during assembly. - As shown in
FIG. 4 , thebracket member 16 is shown operably coupled to asubstrate 8 and operably coupled to anexterior panel 12 in a lateral relationship, and hasinsulation panels 18 vertically disposed on either side of thebracket member 16. In this configuration, thebracket member 16, having low thermal conductivity, creates a thermal break in the path of heat conductivity from theexterior panel 12 to thebuilding substrate 8 in such a way that there is no metal to metal contact. As used herein, the term “thermal break” refers to a break in like materials wherein the material disposed between like materials is comprised of a material having low thermal conductivity such as a polymeric material having a high R-value as further described below. R-values are measurements of the thermal resistance of different materials. R-values are well known by those skilled in the art of the construction and insulation industries. Further, in this configuration, there are no like materials in contact with another, nor is there any metal to metal contact creating a pathway for heat to transfer from the exterior to the interior and vice versa. - As shown in
FIG. 4 , a ventilation system is comprised in part byvents bracket member 16 such that vents 26 are formed between theinsulation panel 18 and theexterior panel 12 and vents 28 are formed between theinsulation panel 18 and thebuilding substrate 8. -
FIG. 5 generally depicts a side elevational view of abracket member 16 which, in this embodiment, has a general Z-shaped configuration with asupport section 32, adapted to connect to and support an exterior cladding unit. In this embodiment, thesupport section 32 of thebracket member 16 includes anexterior surface 34 andinterior surface 36 wherein theinterior surface 36 further comprises a T-shapedchannel 38. Thesupport section 32 has a planar thickness “A” which correlates to the size of thevents 26 which are disposed between theinsulation panels 18 and theexterior panels 12, as shown inFIG. 4 . - As shown in
FIG. 5 , thebracket member 16 further comprises a web orbody section 40 which has afirst side 42 and asecond side 44 wherein anaperture 49 is disposed on thebody section 40 of thebracket member 16 and is configured to housepins 24 which help to hold theinsulation panels 18 in place in assembly. The web orbody section 40 connects thesupport section 32 to theanchor section 48 described below. As shown inFIG. 5 , theaperture 49 further comprises abeveled side 56 disposed on thesecond side 44 of thebody section 40 of thebracket member 16. It is also contemplated that thebeveled section 56 ofaperture 49 can be disposed on thefirst side 42, thesecond side 44, or both the first andsecond sides body section 40 of thebracket member 16 for positively capturing a pin 24 (not shown) with a beveled head that corresponds to the counter sunk beveled edge or edges ofaperture 49. Thebody portion 40 further comprises retention fins or panel piercingairlock ribs 46 which, in this embodiment help to holdinsulation panels 18 in place. It is further contemplated that the insulation panels 18 (not shown) can be manufactured with a channel that corresponds to the fins orribs 46 of thebracket member 16 to retain theinsulation panels 18 in place in assembly. Thebody section 40 of thebracket member 16 has a length “C” which generally corresponds to the width of theinsulation panels 18. Thebracket member 16 further comprises ananchor section 48 having anexterior side 50 and aninterior side 52 which is used to anchor thebracket member 16 to asubstrate 8 withfasteners 20 such as shown inFIG. 4 . Theanchor section 48 of thebracket member 16 has a planar thickness “B” which corresponds to the width of thevents 28 as shown inFIG. 4 in a similar fashion asvents 26 correspond to planar thickness “A” of thesupport section 32. - In the embodiment shown in
FIG. 5 , thebracket member 16 further compriseschannels 58 disposed on both thesupport section 32 andanchor section 48 which are used to guidefasteners FIG. 5 , thesupport section 32 of thebracket member 16 further comprises a T-shapedchannel 38 which is adapted to accept an insert (not shown) which is used to help retain fasteners in assembly as described in more detail below. - In the embodiment shown in
FIG. 5A , abracket member 30 generally has similar features as the bracket shown inFIG. 5 with exception of theexterior side 50 of theanchor section 48 having a T-shaped channel 54 for use in accepting an insert (not shown) which is used to help retainfasteners 20 in assembly. - As shown in
FIG. 6 , thebracket member 16 further comprises a slideable, insert 60 which can be inserted into T-shapedchannel 38 and moved laterally along T-shapedchannel 38 by sliding theinsert 60 along the length of the T-shapedchannel 38 to facilitate fastener retention when fasteners 22 (not shown) are used to secureexterior panels 12 to thebracket member 16. Theinsert 60 can be an insert which can be made of a rigid polymer, metal or other like reinforcing material adapted to rigidity thebracket members 16 and retain fasteners in assembly. Theinsert 60 can also be made from recycled materials such as recycled metal or other like material. The T-shapedchannel 38 disposed on theinterior surface 36 ofsupport section 32 further compriseschannel tabs 39 which positively capture theinsert 60 in the T-shapedchannel 38 while allowing the insert to slide along the length of the T-shapedchannel 38. - In the embodiment shown in
FIGS. , thes 6 and 7anchor section 48 of thebracket member 16 further compriseschannels 62 disposed along theinterior side 52 of theanchor section 48 wherein thechannels 62 vertically span the length of theinterior side 52 of theanchor section 48. Thechannels 62 make up, in part, the ventilation system of this embodiment by providing a cross ventilation air groove for rear ventilating and rain screening of the bracket and panel system. - The
bracket members 16 are developed from an anticorrosive polymeric material that exhibits high insulative qualities or rather, demonstrates high R-value properties such as an R-value in the range of about R1.5 to about R8 per inch. Polymeric materials suitable for the present invention include thermoplastics or thermoset resin materials including for example: acrylonitrile-butadiene-styrene (ABS) copolymers, vinylesters epoxies, phenolic resins, polyvinyl chlorides (PVC), polyesters, polyurethanes, polyphenylsufone resin, polyarylsulfones, polyphthalimide, polyamides, aliphatic polyketones, acrylics, polyxylenes, polypropylenes, polycarbonates, polyphthalamides, polystyrenes, polyphenylsulfones, polyethersulfones, polyfluorocarbons and blends thereof. Other such thermoplastics and thermoplastic resins suitable for the present invention are known in the art which demonstrate high R-values and are thereby heat resistant as well as anticorrosive. Thermoplastics of the present invention are also contemplated using a recyclable polymer or are made of a polymeric material which is partially comprised of a renewable resource such as vegetable oil or the like in its composition when an eco-friendly or “green” bracket member is desired. The polymeric material of the present invention can also be reinforced with a reinforcing fiber as detailed below. Bracket members composed of the materials discussed above form a thermal break between exterior panels and building substrates in an effort to control the temperature within a building structure by reducing or eliminating thermal conductivity from the exterior panel to the building substrate and vice versa. In assembly, the U-value of an exterior wall panel system of the present invention can typically exhibit a U-value from about U1.5 to about U30 depending on the thickness of the overall system, the insulation materials used and the composition of the bracket members. - There are several different types of measurements that relate to a materials ability to insulate, resist, transmit or conduct heat across a material. Particularly, a material’s K-value relates to a specific material’s thermal conductivity, a material’s C-value correlates to the material’s thermal conductance, a material’s R-value relates to a material’s thermal resistance, and a U-value relates to the thermal transmittance of an overall system. In designing a wall, roof or deck bracket and panel system providing adequate insulative properties for a building structure, materials with low K-values and C-values are desired while materials with high R-values are desired. When this set of conditions is met, the overall thermal transmittance, or U-value, of the system is low. Thus, the lower the U-value, the lower the rate heat thermally bridges from one material to another. A building structure having a well insulated system will have a much lower U-value than an uninsulated or poorly insulated system exhibiting high thermal transmittance.
- Regarding the R-value of the bracket members of the present invention, a relatively high R-value is desired to ensure adequate insulation of a building structure from outside elements by making a bracket that creates thermal break in a wall panel system. A range of R-values for the polymeric materials used to construct the bracket members described above would be a range of about R1.5 to about R8 per inch in order to create a thermal break that effectively reduces or eliminates thermal bridging. The thermal conductivity, or K-value, is the reciprocal of the material’s R-value, such that for a polymeric material exhibiting an R-value of about R1.5 to R8 per inch, the correlating K-value for that material would be from about K0.66 to about K0.125 per inch. Thus, in comparison to present day metal brackets used in other bracket and panel systems made of iron or steel, a polymeric bracket member of the present invention will exhibit a K-value of approximately about K.5 to about K0.125per inch at a given set of conditions as compared to a bracket made from a material such as iron or steel which would have an approximate K-value as high as K32 to K60 per inch at the same conditions. This is because iron and steel have low R-values and are well known conductors of heat.
- The bracket members of the present invention are typically molded members which are formed from the materials noted above and generally used in an molding processes such as injection molding, extrusion molding, pultrusion molding and other such molding techniques known in the art. In order to provide a polymeric bracket having comparable strength to the metal brackets known in the art, a reinforcing fiber may be introduced into the polymeric mix to increase the strength of the polymeric bracket member. For example, glass fibers (fiberglass), carbon fibers, cellulose fibers, nylon fibers, aramid fibers, and other such reinforcing fibers can be introduced into the overall polymeric composition before or during the molding process, thereby resulting in a bracket member which has a sufficiently high R-value to create a thermal break in a metal wall system of a building structure, while also having the requisite strength to adequately support exterior panels of a metal panel wall system on a building substrate.
- In the embodiment shown in
FIG. 8 , dotted lines indicate the mounting of anexterior cladding unit 70, shown inFIG. 8 as an exterior panel, to abuilding structure 72. The building structure haswalls exterior panel 70 attaches to the building structure via a bracketing system 80 (FIG. 8A ) which comprises a groovedstud 82 generally made of a polymeric material having a significantly high R-value (as described above for bracket member 16) and clips 84, 86 which are generally made of a metallic material. As shown inFIG. 8A , thestud 82 has afirst end 88 and asecond end 89 which further comprisechannels 92 giving thefirst end 88 and second end 89 a general T-shaped configuration.Channels 92 are U-shaped channels disposed on first andsecond sides 90 and 91 of the groovedstud 82.Clips flanges 94 which coordinate to form a T-shapedchannel 96 which generally correlates to the T-shaped first and second ends 88 and 89 of thestud 82. Theclips U-shaped channels 98 which correlate withU-shaped channels 92 of the groovedstud 82. Thus, the configuration of thestud 82 and theclips clips ends stud 82 as shown inFIG. 9 . Theclips stud 82 further comprises retention fins, or in this embodiment,panel retention fins 102 used to keep insulating materials, such aspanels 104, in place in assembly as shown inFIG. 10 . Thepanel retention fins 102 are disposed on both first andsecond sides 90, 91 of thestud 82. As shown inFIG. 11 , a plurality of bracketingsystems 80 are attached to abuilding structure 72 on the building structuresexterior walls systems 80 are attached to thewall 76 as shown inFIG. 11 , in a vertical stud-like fashion. In this fashion,clip 84 is attached to the building structure substrate orwall 76 at theattachment surface 100 of theclip 84. Thestud 82 is then disposed betweenclip 84 andclip 86 and the clips are attached tostud 82 in the manner shown inFIG. 9 such thatattachment surface 100 ofclip 86 is exposed for the attaching of anexterior panel 70. - As shown in
FIG. 12 , theexterior panel 70 is attached to a plurality of bracketingsystems 80 byfasteners 106. Between bracketingsystems 80, apanel 104 is disposed wherein thepanel 104 is made of a material similar to thepanels 12 as described above. In this configuration, thestud 82 creates a thermal break between theexterior panel 70 and thebuilding substrate 76. Further, in this configuration, there are no like materials in contact with another, nor is there any metal to metal contact creating a pathway for heat to transfer from the exterior to the interior and vice versa. - As shown in
FIG. 12A , abracketing system 80 is shown attached to asubstrate 76 via aclip 84 through fasteners (not shown) and further attached to anexterior panel 70 viaclip 86 usingfasteners 106. Thepanel retention fins 102 are shown fitting intogrooved channels 108 formed in thepanel 104 to help align thepanel 104 in assembly. A ventilation system includesvents 110 and 112, which correlate to the thickness of attachment surfaces 100 ofclips panel 104 and thesubstrate 76 and vent 112 is disposed betweenpanel 104 andexterior panel 70. - In another embodiment of the present invention, a
polymeric bracket member 114 is shown as a hat-shaped bracket member, or girt (FIG. 13 ). In this embodiment, thebracket member 114 comprises first and second bottom anchor flanges orsections exterior sides interior sides channels 128 are disposed on theinterior sides anchor flanges channels 128 havechannel tabs 129 which are used to positively capture aninsert 130 in assembly.Fastener guide channels 132 are disposed on the exterior andinterior sides bottom anchor flanges bracket member 114 further comprises first and second webs orside walls panel retention fins 138 disposed on either side ofside walls bracket member 114 further comprises atop support section 140 which has anexterior side 142 and aninterior side 144. Both the exterior side and the interior side havefastener guide channels 132 and theinterior side 144 further comprises a T-shapedchannel 146 havingtabs 148 for positively capturing a variable gauge insert (not shown) in assembly. - As shown in
FIG. 13A ,bracket member 114 is shown in a wall assembly wherein thebracket member 114 is attached to abuilding substrate 154 atbottom anchor flanges Panels panels 150 span betweenbracket member 114 and another like bracket member 114 (not shown).Panel 152 is disposed in a channel formed betweenside walls bracket member 114. Anexterior panel 156 is attached totop support section 140 ofbracket member 114 viafasteners 158. A ventilation system further includesvents 160, which are formed betweenpanels 150 andexterior panels 156, for ventilation and rain sheeting of the system.Vents 164 are formed between thepanels 150 and thebuilding substrate 154 for cross-ventilation and moisture sheeting purposes and vent 162 is formed betweenpanel 152 and thebuilding substrate 154 for ventilation within the interior space ofbracket member 114. In this configuration,bracket member 114, formed from a polymeric material having a high R-value, forms a thermal break between theexterior panel 156 and thebuilding substrate 154. Further, in this configuration, there are no like materials in contact with another, nor is there any metal to metal contact creating a pathway for heat to transfer from the exterior to the interior and vice versa. - As shown in
FIGS. 14 and 15 , thebracket member 114 is shown withinserts 160 to be inserted in the T-shapedchannels 128 disposed on theinterior sides bottom anchor flanges channel tabs 129. Theinserts 160 are made of a rigid material, such as a rigid polymer or metallic material and are slideable along the length of the T-shapedchannels 128. Further, it is contemplated that a similar insert (not shown) can be inserted in the T-shapedchannel 146 disposed on theinterior side 144 of thetop support 140 ofbracket member 114. As with thebottom anchor flanges top support 140 haschannel tabs 148 disposed on theinterior side 146 of thetop support 140, which hold an insert (not shown) in place in assembly. An insert used in the T-shapedchannel 146 is slideable along the length of thechannel 146 to a desired location where fasteners (not shown) will be used to hold an exterior panel (not shown) in place ontop support 140. Theinserts 160, as well as the insert used in T-shapedchannel 146, are used to retain the fasteners in place in assembly. - The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principals of patent law, including the Doctrine of Equivalents.
Claims (20)
1. A system for supporting exterior cladding units on a substrate of a structure, comprising:
a polymeric bracket system comprising a plurality of polymeric bracket members, wherein each of the bracket members includes at least one anchor section, at least one web section and at least one support section, wherein the at least one anchor section attaches to the substrate, the at least one web section operably connects the at least one anchor section to the at least one support section, and the at least one support section supports the exterior cladding unit;
each of the polymeric bracket members providing a thermal break from the exterior cladding units to the substrate;
each of the polymeric bracket members mounted to the building structure for mounting the exterior cladding units to the bracket members thereby forming channels disposed between the exterior cladding units and the building substrate when the exterior cladding units are mounted to the polymeric bracket members; and
a ventilation system having a plurality of vents formed by the mounting of the exterior cladding units to the polymeric bracket system.
2. A system according to claim 1 , wherein the channels disposed between the exterior cladding units and the building substrate house insulation materials.
3. A system according to claim 2 , wherein the insulation materials are selected from the group consisting of insulation panels, foam, fiberglass insulation, rigid insulation, semi rigid insulation, blanket insulation, loose fill insulation, spray foam in either fiberglass, rock wool, cellulose based, polystyrene, polyisocyanurate, polyurethane or other polymeric insulation formulation.
4. A system according to claim 3 , wherein the insulation materials are insulation panels.
5. A system according to claim 4 wherein the at least one web section further comprises retention ribs.
6. A system according to claim 1 wherein the at least one anchor section further comprises guide channels.
7. A system according to claim 2 , wherein the plurality of vents of the ventilation system comprise:
a first group of vents disposed between the insulation materials and the exterior panels; and
a second group of vents disposed between the insulation materials and the substrate.
8. A system according to claim 7 , wherein the plurality of vents of the ventilation system further comprise:
lateral channels disposed on the at least one anchor section of the polymeric bracket members.
9. A system according to claim 1 wherein the at least one web section further comprises apertures and retention pins.
10. A system according to claim 1 wherein the polymeric bracket members have an R-value in the range of about R1.5 to about R8 per inch.
11. A system according to claim 9 wherein the polymeric bracket members are comprised of a polymeric material selected from the group consisting of thermoplastics, thermoset resins, acrylonitrile-butadiene-styrene (ABS) copolymers, vinylesters epoxies, phenolic resins, polyvinyl chlorides (PVC), polyesters, polyurethanes, polyphenylsufone resin, polyarylsulfones, polyphthalimide, polyamides, aliphatic polyketones, acrylics, polyxylenes, polypropylenes, polycarbonates, polyphthalamides, polystyrenes, polyphenylsulfones, polyethersulfones, polyfluorocarbons and blends thereof, wherein the polymeric material is reinforced with a reinforcing fiber selected from the group consisting of fiberglass, carbon fibers, cellulose fibers, nylon fibers, and aramid fibers.
12. A polymeric bracket member, comprising:
at least one anchor section;
at least one support section;
at least one web section;
the anchor section having at least one channel;
the support section having at least one channel; and
the at least one channel of the support section adapted to retain an insert.
13. A polymeric bracket member according to claim 12 wherein the polymeric bracket member has an R-value in the range of about R1.5 to about R8 per inch.
14. A polymeric bracket member according to claim 12 wherein the polymeric bracket member is comprised of a polymeric material selected from the group consisting of thermoplastics, thermoset resins, acrylonitrile-butadiene-styrene (ABS) copolymers, vinylesters epoxies, phenolic resins, polyvinyl chlorides (PVC), polyesters, polyurethanes, polyphenylsufone resin, polyarylsulfones, polyphthalimide, polyamides, aliphatic polyketones, acrylics, polyxylenes, polypropylenes, polycarbonates, polyphthalamides, polystyrenes, polyphenylsulfones, polyethersulfones, polyfluorocarbons and blends thereof, wherein the polymeric material is reinforced with a reinforcing fiber selected from the group consisting of fiberglass, carbon fibers, cellulose fibers, nylon fibers, and aramid fibers.
15. A polymeric bracket member according to claim 12 wherein the at least one web section further comprises ribs adapted to retain insulating materials.
16. A polymeric bracket member according to claim 12 wherein the at least one anchor section further comprises guide channels.
17. A polymeric bracket member according to claim 12 wherein the at least one channel of the at least one anchor section is adapted to retain an insert.
18. A bracketing system, comprising:
a grooved polymeric stud;
first and second clips operably coupled to the stud;
the first and second clips further comprising attachment surfaces;
the first and second clips further comprising channels.
19. A bracketing system according to claim 18 wherein the grooved polymeric stud has an R-value in the range of about R1.5 to about R8 per inch.
20. A bracketing system according to claim 19 wherein the grooved polymeric stud is comprised of a polymeric material selected from the group consisting thermoplastics, thermoset resins, acrylonitrile-butadiene-styrene (ABS) copolymers, vinylesters epoxies, phenolic resins, polyvinyl chlorides (PVC), polyesters, polyurethanes, polyphenylsufone resin, polyarylsulfones, polyphthalimide, polyamides, aliphatic polyketones, acrylics, polyxylenes, polypropylenes, polycarbonates, polyphthalamides, polystyrenes, polyphenylsulfones, polyethersulfones, polyfluorocarbons and blends thereof, wherein the polymeric material is reinforced with a reinforcing fiber selected from the group consisting of fiberglass, carbon fibers, cellulose fibers, nylon fibers, and aramid fibers.
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US17/874,079 US20230047802A1 (en) | 2011-01-04 | 2022-07-26 | Polymer-based bracket system for metal panels |
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US17/874,079 Pending US20230047802A1 (en) | 2011-01-04 | 2022-07-26 | Polymer-based bracket system for metal panels |
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US16/512,626 Active US11396757B2 (en) | 2011-01-04 | 2019-07-16 | Polymer-based bracket system for metal panels |
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US9617739B2 (en) | 2017-04-11 |
US20150121787A1 (en) | 2015-05-07 |
US9957721B2 (en) | 2018-05-01 |
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US20180245350A1 (en) | 2018-08-30 |
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US8826620B2 (en) | 2014-09-09 |
US20170198481A1 (en) | 2017-07-13 |
US20210180329A1 (en) | 2021-06-17 |
US10370858B2 (en) | 2019-08-06 |
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