US20230340780A1

US20230340780A1 - Contoured rails for mounting wall panels or insulation unto an existing wall

Info

Publication number: US20230340780A1
Application number: US17/857,391
Authority: US
Inventors: Henry H. Bilge
Original assignee: Individual
Current assignee: Individual
Priority date: 2022-04-20
Filing date: 2022-07-05
Publication date: 2023-10-26

Abstract

Disclosed is a system of cladding along an existing exterior wall of a building featuring a plurality of U-shaped or Hat-Shapped rails shown as affixing rails 90 and 10, respectively, or H-shaped rails, shown as affixing rails 200, deployed in a substantantially parallel and spaced apart arrangement, with an insulation panel in between two of plurality of U-shaped or H-shaped rails. The U-shaped and H-shaped components both serving as affixing rails for securing insulation in the space between an existing wall and decorative or finishing wall panels using holding elements, such as a plurality of pegs or rods. The H-shaped affixing rail is further described in combination with edge-components. The edge components are necessary to absorb and build around corners and window or door apertures along the surface of an existing wall.

Description

CLAIM OF PRIORITY

The current application claims priority of the U.S. Design application No. 29/835,659 filed on Apr. 20, 2022, and also claims priority of the U.S. Design Application No. 29/836,135 filed on Apr. 25, 2022, and also claims priority of the U.S. Design Application No. 29/836,224 filed on Apr. 25, 2022, and also claims priority of the U.S. Design Application No. 29/836,222 filed on Apr. 25, 2022, the contents of all of the above listed applications are filly incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to a wall system, and more particularly, to a system for easily mounting wall panels over an existing wall while concealing exterior insulation.

BACKGROUND OF THE INVENTION

The present invention relates generally to a wall system, and more particularly, to a system for easily mounting wall panels over an existing wall while concealing exterior insulation.
Present construction methodologies often require the erection of the main shell construction that represents the main weight bearing structure of the building. The structure often includes some structural core or a latticework of load bearing elements, girted by an exterior wall that also serves as mount points for exterior doors and windows. The material used for a wall of this type may be wood, brick, concrete, metal frame of some composite thereof.
The exterior shell is not the final façade of a building. The materials used for erecting walls are not made to possess the visually pleasing aesthetics that would be acceptable as a final product. Furthermore, the shell must still be weather proofed and insulated from the exterior. For these reasons, building are clad in externally facing panels of a plurality of materials that give each completed building their unique design and character.
What takes place between the existing load bearing shell and outer wall paneling makes all the difference. There are disparate methodologies in existence, each having their pros and cons. Most existing methodologies are complex, having many individual parts and assemblies, or too heavy, placing undue strain on the outer skin of the building, or are too fragile and are suitable only for the lightest forms of exterior paneling or for relatively low height structures. The state of the art therefore calls for a compact and easily deployed solution that is capable of improved load bearing capabilities.
Furthermore, a proposed solution must a plurality of wall cladding types, while also providing means for air and water ventilation to keep elements hidden between the exterior wall membrane and exterior wall panels free of mold, mildew and material degeneration inherent with long term effects of perpetual dampness. Therefore, a solution must enable effective air and water circulation and an enforcement of an air gap between insulation materials and exterior wall paneling.
A gap between insulation materials and outer wall panels is also highly desirable to promote conservation of energy inside building structures. Due to the principal of conduction, even insulation will eventually transfer hot or cold temperatures onto a surface it is insulating and thus eventually lose some of its effectiveness. To overcome the loss of insulating efficiency caused by conduction, sound construction practices recommend creating an air gap between an exterior layer of exterior insulation and the layer of exterior wall paneling. This air gap creates a reflective barrier, where the hot or cold air radiating from the exterior wall panel is reflected by the insulation layer due to the presence of the air gap.
Enforcement of the air gap between the insulation layer and the exterior wall paneling is a known practice that is often dictated by the building code. However, there is presently no standard and failsafe compliance method. Instead, contractors attempt to comply by inserting a separate strip of material between the exterior paneling and the insulation. Existing methods have several serious shortcomings. The first one is higher cost and length of installation. The cost is increased due to the requirement of purchasing, stocking and components required in ensuring that a gap is present. Secondly, installation requires a separate step involving a non-standard component. Third, it is often difficult to keep the thickness of the air gap uniform when utilizing non-standard and disparate components. Finally, the presence of an additional structural component adds to the complexity of a project and increases the risk of mistake or accident occurring due to the additional level of complexity.
Furthermore, just the presence of a gap may not be sufficient in some situations. For example, certain facades will permit a small amount of water to trickle through and behind wall cladding. This moisture needs to have a drainage outlet and must be completely ventilated to discourage accumulation of damaging moisture, mold, or mildew. Existing solutions do not adequately address the problems identified above.
It is therefore desirable to provide a system that creates a single structural component which form a frame for attaching exterior insulation to an existing wall, which also serves as a point of attachment of exterior paneling, and which enforces a uniform air gap between the exterior paneling and the layer of insulation.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a simple, yet high strength system of rails capable of mounting wall cladding onto an existing wall, while also securing insulation in the space between the exterior wall paneling and an existing wall.
It is still another object of the present invention to provide a rail system that offers mount points for holding elements that secure insulation to the exterior of an existing wall without penetrating the moisture membrane to do so. The same rail system is then also used to securely mount wall paneling to complete the exterior appearance of a building in a durable and long-lasting fashion.
It is still another object of the disclosed invention to describe a simple and uniform means of ensuring that an air gap exists between an exterior or cladding covering and a layer of exterior insulation.
It is another object of the present invention to provide a sustainable and adequate airflow between cladding panels and insulation, which among other benefits, prevents unchecked moisture buildup.
It is still another object of the present invention to provide a first moisture gap that is enforceable by the shape of the Z-girt or Z-shaped component holding the insulation panels and exterior wall panels
It is still another object of the present invention to provide a wide first moisture gap above the insulation panels and below the cladding panels, and a second moisture gap between the insulation panels and an existing wall of the structure.
It is still another object of the present invention to provide way of retaining insulation panels between two neighboring Z-shaped components by use of a rod spanning the two Z-shaped components.
It is still another object of the present invention to enable the use of insulation panels of varying thickness, where the panels are nonetheless securely retained between the Z-shaped components through use of rods of various thicknesses or diameters.
The disclosed invention is a system of securing wall panels unto an exterior wall. A suitable context for installing the disclosed system may be as a support for façade cladding or to support interior wall paneling. The disclosed system is made of several variants that all accomplish the same goal, which is to improve ease of installation without increasing costs, while also achieving a green technological goal of improving efficiency of climate control systems by enforcing strict air gap conditions between insulation and wall paneling.
The first disclosed variation describes a plurality of affixing rails. Each one of the affixing rails is configured to be attached or securely fastened onto an existing wall. Such a wall may be an interior or an exterior wall, made of wood, metal, cinderblocks or concrete slab. The affixing rails are installed in a row or series of individual rails that are placed adjacently, but in a spaced apart association with each other.
Each individual affixing rail is comprised of at least two first forward walls, extending forwardly at an angle, preferably a right angle, from an existing wall onto which the rail is mounted. The first forward walls are preferably paced in a spaced apart orientation with each other. At the bottom edge of one or both of the first forward walls is a base wall which issues laterally and at an angle, preferably a right angle, from the first forward wall from which it issues or onto which it is attached. The base walls extend outwardly in a sideways direction away from each of the first forward wall. The bottom surface of the base walls is placed against the surface on existing wall, with the top surface facing outward. The base walls are then used to fasten the affixing rail to an existing wall.
Joining the two first forward walls together is a second wall. This configuration causes the second wall to be in a substantially parallel and spaced apart association with an existing wall. The two first forward walls and the second wall that joins them, form a first channel that opens towards the wall onto which the affixing rail is mounted. The base wall or walls extend obliquely and away from the first channel. The first rail can be filed with a segment of insulation material. The space between any two affixing rails is preferably covered with insulation material, where each end of a segment of such insulating material is forced into the space between a first forward wall of one affixing rail and a first forward wall of an adjacent affixing rail.
It is preferred that the second wall further comprises one or more second channel. A second channel may be in a form of two beveled walls, where opposing beveled slopes run along the entire length of the second wall and are separated by a trough wall. The second channel may also be a v-grove, a cove grove or a u-groove. The trough wall of the second channel, or the lowest section of the groove forming the second channel, impinges into the airspace of the first channel, thus creating a strength rib that preferably runs along the entire length of the second wall or along segments thereof.
The first forward walls further contain a plurality of ventilation and drainage openings or slots running at an angle across the width of the first forward walls. Such drainage openings are used to promote air and moisture circulation between the top of insulation material and exterior wall panel mounted onto the affixing rails. The drainage openings may be oriented vertically across the width of the first wall, or at a certain angle that is off vertical, and are spread across the first forward wall. In combination with the drainage openings or as separate slots, the first forward wall preferably also contains holding slots. The holding slots may also be used as drainable openings for air and water circulation but are primarily intended to mount holding elements.
The holding elements may be a peg, where a first portion of each peg is inserted into one of the plurality of the holding slots, with a second portion protruding out of the holding slot and securing the top surface on insulation material or insulation panel, preventing the insulation from coming out of the area between the affixing rails and maintaining the air gap between an exterior wall panel and the top surface of an insulation panel. The holding element may also be a rod, spanning the space between two adjacent affixing rails, where the first portions of such rod are inserted into the holding slots with the second portion pressed against the top surface of an insulation panel. Holding element may also be a combination of pegs and rods. It should be noted that the holding slots are preferably disposed along one or more co-planar levels that define the thickness of the insulation panel used, or the thickness of the air gap.
Disclosed further is another useful and non-obvious system of securing insulation and wall panels unto an existing wall with help of a plurality of affixing rails. It should be noted that the affixing rails are spaced apart from each other in a parallel association, or at an angle to each other, such as a right angle, or otherwise as necessitated by the shape and features of a wall bearing the disclosed system. In this embodiment, each affixing rail in the plurality of affixing rails has a base wall, which is preferably uniform or planar. The bottom surface of the base wall is placed against an existing wall of a structure. Fasteners are then driven into from the top surface and through the base wall to attach the affixing rail to the existing wall. The base wall may also be attached using adhesives, welding or cementing.
A first forward wall extends forwardly from the top surface of the base wall. A second wall then extends laterally at an angle, preferably a right angle, in first and second directions from the free end of the first forward wall. The second wall preferably runs parallel to the base wall. The first and second directions of the second cantilever on either side of the first forward wall
Further, two or at least two second walls extend forwardly from the front surface of the second wall. The second walls are preferably oriented in a parallel and spaced apart configuration with each other. A side wall then extends laterally and at an angle, preferably a right angle, from a free end of each of the second walls. As such the side walls overhang the base wall and are substantially parallel with the base wall. The two second walls and the front surface of the second wall form an inverted channel that faces the wall panels that are mounted onto the front surface of the side walls. The width of the second walls is directly proportional to the depth of the inverted channel.
The back surface of the second wall, the first forward wall and the top of the base wall create a cove or cavity which is used to retain an end a section of insulating material. In the disclosed affixing rail, a first cavity exists on the first side of the first forward wall and the second cavity on the other side, on the second side of the first forward wall.
It is preferred that the first forward wall further comprises one or a plurality of drainage openings. Shown in the figures is are drainage openings running across the width of the first forward walls. The drainage openings are intended to create air and water drainage and circulation in the space between adjacent affixing rails.
A plurality of holding slots may be created in a co-planar and multi-level orientation along the length of the first forward wall. These holding slots, which may be intersecting the drainage openings are then used to hold the first portion of a holding element. Each holding slot may accommodate one or more first portions of the holding element, with the first portion being the part of the holding element inserted and retained with the holding slot.
The preferred holding element disclosed in this invention is a peg or a rod, or a combination of the two. Holding elements may also be a length of a wire or ribbon that would have a rigid first portions on either of its ends, which are then inserted into the holding slots of adjacent affixing rails. The holding element is mounted above the top surface of an insulating material, to hold said insulating material in place.
In this alternative embodiment of the disclosed system of securing insulation and wall cladding onto an existing wall, the plurality of adjacent affixing rails is edged in within a segment of an existing wall using edge rail. Each edge rail is formed with a base wall. The base wall has a top surface and a bottom surface. The bottom surface is parallel with an existing wall and is affixed to it using fasteners driven through the base wall or using adhesives or cement attaching the bottom surface to an existing wall. A first forward wall extends forwardly at an angle, preferably a right angle, from the top surface of the base wall. A second wall then extends from a free end of the first forward wall in the same direction as said base wall. A second forward wall extends forward at an angle from a free end of the second wall. And a side wall extending laterally and at an angle from the free end of the second forward wall. As such the side wall is substantially parallel and in set apart association with the base wall. As such, the second wall, the first forward wall and the top surface forming a first cavity, where the first cavity opens toward an adjacent affixing rail that is set off at a distance from the edge rail. The space or distance between the edge rail and the adjacent affixing rails is able to retain a length of an insulating material. Thus a second cavity of the adjacent affixing rail retains an end of the insulating material, while the first cavity of the edge rail retaining an opposing end of the insulating material. The wall panels are then fastened to side wall of the edge component.
The first forward wall of the edge component further contains openings or slots to promote air and moisture circulation. These openings may be elongated or an any other shape and run across the entire length of the first forward wall. In addition to these openings or drainage slots, the first forward wall is further comprised of a plurality of holding slots for holding elements that secure insulation against the existing wall within the distance between the edge rail and the adjacent affixing rail. It is preferred that the holding slots along the first forward wall of the edge component are co-planer with each other at one or more distances from the base wall. The holding slots of the edge component are also preferably co-planar with holding slots of the adjacent affixing rail. Thus a holding element that is a slot then extends the distance between the edge rail and affixing rail or two adjacent affixing rails and is held withing holding slots of the two adjacent rails, either edge or affixing rails, whichever it may be.
It is the purpose of the disclosed invention to create a system of affixing rails for securing insulation and wall paneling onto an existing wall.
It is another purpose of the disclosed invention to create a system of affixing rails that were both rigid and easily mountable.
It is still another purpose of the present invention to create a system that incorporates holding elements that is configured to secure insulation to the outer surface of an existing wall easily and without the use of permanent fasteners driven into the existing wall itself.
It is still a further purpose of the present invention to create a system that limits the likelihood of moisture penetration of an existing wall by limiting the number and purpose of fasteners piercing the exterior surface of such wall.
It is still another purpose of the present invention to create a system that enforces an air gap between insulation and outer wall cladding.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional diagram of an assembled disclosed system.

FIG. 2 is another cross-sectional diagram of an assembled disclosed system.

FIG. 3 is a top perspective view of an embodiment of affixing rail.

FIG. 4 is a back perspective view of an embodiment of affixing rail shown in FIG. 3 .

FIG. 5 is an elevational view of the embodiment of affixing rail shown in FIG. 3 .

FIG. 5A demonstrates an alternative embodiment of the affixing rail shown in FIG. 3 having additional drainage and air circulation openings along the second wall.

FIG. 5B is a contextual diagram of the embodiment shown if FIG. 5A.

FIG. 6 demonstrate an alternative of the affixing rail shown in FIG. 3 that is intended as an edge component, but which may be used as a main affixing rail as well.

FIGS. 7, 8 and 9 are diagrams of fully assembled segments of the disclosed system demonstrating the use of a holding element that is a plurality of pegs.

FIG. 10 is a diagram of another holding element, in this case a plurality of rods.

FIG. 11 is a cross sectional diagram of another embodiment of the disclosed system.

FIG. 12 is a cross sectional diagram of the embodiment shown in FIG. 11 featuring a shallow inverted channel.

FIG. 13 is a detailed perspective diagram of the H-rail affixing rail.

FIG. 14 is an elevational view of the affixing rail shown in FIG. 13 .

FIG. 15 is a side plan view of the affixing rail in a shape of an H-rail showing a plurality of opening and retaining slots.

FIG. 16 is a contextual diagram showing an assembled system of rails described in FIGS. 11-15 .

FIG. 17 is an alternative embodiment of the affixing rail shown in FIG. 13 having additional air openings.

FIGS. 18 and 19 are additional angles of the embodiment of the affixing rail shown in FIG. 17 .

FIG. 20 is a contextual diagram of the embodiment demonstrated in FIGS. 18 and 19 .

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.
Reference will now be made in detail to embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.
FIG. 1 discloses a cross-sectional diagram of a system that enables installation of wall cladding panels 60 and/or insulation material 64 onto an existing wall 62 by deploying a plurality of affixing rails 10 at a distance and angle from each other. Each affixing rail 10 is preferably comprised of two first forward walls 20. As shown, the two first forward walls 20 are of substantially equal width 21 and are in a spaced apart orientation with each other. Preferably the two first forward walls 20 are parallel to each other.
The width 21 is the distance between the fist edge 22 and the free end of the first forward wall 24. Extending from the first edge 22 is a base wall 30. The first wall 30 extends at an angle from the first forward wall 20, preferably a right angle. The base wall 30 has the bottom surface 32 and the top surface 34. The bottom surface 32 is preferably parallel with the existing wall 62 The top side 34 facing the bottom surface 63 of the insulation panel 64. The top side 34 and the bottom side 62 may be parallel to each if the thickness of the base wall 30 is uniform. There is at least one base wall 30. The affixing rails 10 shown in FIG. 1 are comprised of two base walls 30 at each first edge 22. Also shown is the second wall 40, having the raised surfaces 40 a and recessed surfaces, such as the trough wall 47 c. A plurality of fasteners 50 b secure a wall panels 60 to the second wall 40. Notably, the fastners 50 b secure the holding element 70 (shown as a rod 100) as well by perforating the pin section 72 b. The holding element 70 mounted through retaining slots 27 is utilized to secure insulration 64, and 66 within the first channel 45 by using the pin sections 72 b, and to ensure the presence of an air gap 67 of at least the thickness of the rod 100 between the wall panels 60 and the insulating material 64.
FIG. 2 demonstrates the affixing rail 90, which may be used as an edge component or as an alternative to the affixing rail 10. The plurality of affixing rails 10, or a combination of affixing rails 10 or 90, or plurality of affixing rails 90, is shown fastened to the existing wall 62 using fasteners 50 a that are driven through the base walls 30. Alternatively, the bottom surface 32 may be securely attached to an existing wall (supporting wall) 62 using adhesives or cement or using an adhesive compound in combination with a fastener 50 a. The second wall 40 joins the two first forward walls 20, with the first forward walls and the second wall 40 forming a first channel 45.
The space 74 between two adjacent affixing rails 10, or an affixing rail 10 and an adjacent edge member affixing rail 90 may be filled with a section of an insulating material 64. The distal ends 65 of the insulating material 64 are wedged against the first forward walls 20 that border the space 74. An additional section of insulating material 66 may also inserted into the first channel 45.
The retaining slots 27 perforate through the first forward walls 20 and are used as mount points for the for holding element 70. The holding element 70 shown in FIGS. 1 and 2 is a rod 100. The rod 100 spans the entire space 74 and is mounted across adjacent affixing rails 10 by having pin sections 72 a and 72 b inserted into retaining slots 27 that are co-planar between the two adjacent affixing rails 10. It should be noted that raining slots 27 are preferably set at least two co-planar levels. For example, the lower co-planar level 27 a and an upper co-planar retaining slots 27 b that are shown housing the pin sections 72 a and 72 b. The holding element 70 is used to secure a section of insulation 64 without needing the perforate the surface 62 a of an existing wall. By this point in the process of construction, the surface 62 a of the wall 62 would already have some form of weatherproof membrane and fewer perforation instances of such membrane are highly beneficial to the overall moisture exclusion qualities of the disclosed system. The holding element 70 is also useful in enforcing the air gap 76 between the insulating material 64 and the finishing wall panel 60. Not that the pin sections 72 a and 72 b double as holding elements for the insulation material 66 that is inserted within the first channel 45. The insulation material 64 of 66 may be a substantially inflexible insulation panel or a soft and pliability insulation material.
FIG. 3 demonstrates the top view of the affixing rail 10. Shown are first forward walls 20 that are in a spaced apart and parallel association with each other and joined together at their free ends 24 by the second wall 40. Extending sideways and at an angle from the bottom edge 22 of the first forward walls 20 are the side walls 30. The first forward walls 20 contain a plurality of air and moisture openings 28. The openings 28 may be elongated, circular, triangular or in any other shape. While the openings 28 placed across the width of the first wall 20, these can be placed on a diagonal, a circular or wave pattern or a lengthwise opening. The retaining slots 27 are shown intersecting the air and moisture openings 28. Alternatively, the retaining slots 27 may exist independently and separate from the air and moisture openings 28.
As seen between FIGS. 3 and 4 both first forward walls 20 contain the air and moisture openings 28 and these openings 28, and the retaining slots 27 perforate the first forward walls 20 to the other side. Furthermore, the retaining slots 27 are preferably arranged co-axially along the same first forward wall 20 and preferably symmetrically and co-axially across parallel first forward wall 20 of the same affixing rail 10 and an adjacent rail 10. The purpose for symmetrical alignment of at least the retaining slots 27 is to enable to for holding elements 70 to be installed spanning a space 74 between adjacent affixing rails 10. The openings for air and moisture 28 are preferably also symmetrical and aligned across the plurality of affixing rails 10 but may also be arranged in a more random fashion.
As shown in FIGS. 3, 4 and FIG. 5 . The second wall 40 preferably contains a second channel 46. As shown in FIG. 5 , the second channel is formed using beveled slopes 47 b and 47 a, which are opposing slopes and are separated by a trough wall 47 c. The beveled slopes 47 a and 47 b and the trough wall 47 c create a second channel Preferably, the second wall 45 has at least one second channel. The second channel may also be formed in the shape of v-grove, a cove grove or a u-groove. The trough wall 47 c impinges into the first channel 45 and preferably runs along the entire length of the second wall 40, creating a strength rib throughout the second wall 45. The raised surfaces 40 a are then used to mount insulation panels 60 using fasteners 50 b (FIG. 1 ). The second channel may also create a raised surface along the second wall 40 by having the second channel 46 face in the same direction as the first channel 45.
Additional air openings may be introduced throughout the affixing rail 10. Shown in FIG. 5A is an affixing rail 10, the base walls 30, the first forward walls 20 and the second wall 40. The air and moisture openings 28 are shown as oval. These openings may also be circular, square, triangular, or any other shape, such as a star or moon shape. The retaining slots 27 are shown as separate slots from moisture openings 28, where retaining slots 27 a form the lower co-planar slots and retaining slots 27 b form the upper co-planar slots. Additional or fewer co planar levels of retaining slots 27 may be provided. The second wall sections 40 a that do not make up the second channel 46 are shown having additional openings 28 a. Additional air and moisture openings 28 a may be utilized for circulation as well as to gain access into the first channel 45, for example to fasten or adjust insulating material inserted therethrough. Additional openings may be provided along the second channel 46.
FIG. 5B now demonstrates contextually the at least two affixing rails 10 mounted in a spaced apart, and preferably parallel, association to each other, having a space 74 between each affixing rail 10. While only two affixing rails 10 are shown in the present diagram, it should be noted that the deployment of affixing rails 10 would continue on eather side of the two affixing rails 10 shown, at similar internvals, or at intervals and angles as desired or dictated by the topology of the wall 62. The plurality of additional openings 28 a provide access into the first channel 45. The plurality of openings 28 and 28 a further decrease the weight of the affixing rail 10.
FIG. 6 demonstrate the affixing rail 10 having a base wall 30, two first forward walls 20, joined by the second wall 40. As in prior figures, it is preferred that both first forward wall 20 contain symmetrical air and moisture openings 28 as well as retaining slots 27. The symmetrical orientation of openings promotes air circulation and water drainage. The affixing rails 10 of the affixing rail 90 is preferably made of composite, thermally non-conductive materials such as fiberglass and other synthetic substances. The affixing rails 10 may also be made from standard building materials such as metal alloys.
FIG. 7 displays a contextual representation of a plurality of affixing rails 10. The affixing rails 40 would be mounted onto an existing wall 62. Each affixing rail 10 would be separated from an adjacent affixing rail 10 by a space 74, until the system would span the entire desired surface 62 a. The affixing rails 10 may be placed in a parallel association with each other or at an angle to adjacent affixing rails 10. This is especially true when framing around a doorway or a window, or a structural irregularity of an existing wall. While the wall 62 is shown having upright elements 120 supporting wall paneling 122, the same mounting techniques are employed for walls 62 made entirely of brick, concrete slab or iron sheeting or beams.
The space 74 is preferably covered by an insulating material 64, with additional material inserted into the first channel 45 of each affixing rail 10. The thickness of an insulating material 64 determines which co-axial retaining slots 27 are exposed and are therefore used to secure the insulating material 64. Then each, or some number of the retaining slots 27 would be engaged with a holding element, which in the case of FIGS. 7 and 8 are pegs 110. Each peg 110 is comprised of the pin section 112 which is the surface that engages the retaining slot 27, a flange 113 to control the degree of insertion of the holding peg and the actual holding surface 114. The peg 110 is preferably kept in place either a snug fit within a retaining slot 27, or by an outward pressure exerted on the peg 110 by the insulation panel 64, or by a combination of these factors. Once fully inserted into the retaining slot 27, only the holding surface 114 protrudes above the affixing rail 10, as shown in FIG. 8 . Also seen from FIG. 8 is that the engaged retaining slots are the upper retaining slots 27 b. If the insulating material would have been thinner, lower retaining slots 27 a would have been used. There may be one or multiple levels of retaining slots 27 to accommodate insulating materials 64 of various thicknesses. It should be noted that insulating material 66 within the first channel 45 is held in place by the inserted pin section 112 that is now within the airspace of the first channel 45. While not shown, the affixing rails 10 and the insulation paneling 64 would then be covered external wall panels that are fastened to the second wall 42.
FIG. 9 demonstrates a combination of affixing rail 10 and an edge affixing rail 90. In this embodiment the systems of plurality of affixing rails 10 shown in FIGS. 7 and 8 may cover the majority of a wall 62, with the edge affixing rail 90 being placed adjacently and in a spaced apart association with the affixing rail 10 nearest to an edge 63 or near a structural element, such as a window or door aperture, or an interruption due to a ledge, balcony or bend in the wall 62. Alternatively, the affixing rail 90 may be used to cover the entire surface of a wall 62 in place of the affixing rail 10.
The holding element 70 may be in the form of a rod 100, as shown in FIG. 10 . The rod 100 spans the space 74 between two affixing rails 10, or between the affixing rails 10 and 90. The pin portions 72 a and 72 b are mounted within retaining slots 27 in this case, the upper retainer clots 27 b of two adjacent affixing rails 10. The pin portions 72 a and 72 b are used to secure the rod 100 and also to secure the insulating material 66 inside the first channels 45. The holding area 102 of the rod 100 is then used to secure the insulation material 64 within the space 74. The rod 100 is especially suitable for use with software and more malleable insulating materials. The rod 100 and the pegs 110 may be used in combination with each other. The holding portion 102 may be replaced with a cable, coil or ribbon.
FIG. 11 demonstrates another embodiment of a plurality of affixing rails. In this case, the system would be comprised of a plurality of affixing rails 200 (which shall sometime be referred to as H-rails) positioned along the surface 62 a of an existing wall 62 in an adjacent and spaced association with each other, until the entire surface of an existing wall 62 is suitably encased using the system disclosed in this figure. The affixing rail 200 that is nearest to the edge of a wall 63 would preferably be in an adjacent and spaced apart association with an edge component 300. The wall edge 63 possibly being an interruption in the wall, a corner, an aperture, a bend in the wall, or a protrusion or a recess,
The affixing rail 200 or an H-rail is comprised of a base wall 220. The base wall having a bottom surface 222 and a top surface 223. The bottom surface 222 is preferably parallel to an existing surface 62 a of a wall 62 and is placed against the wall 62. The top surface 223 supports the bottom of an insulating material 64. The base wall 220 is fastened to a wall 62 utilizing a plurality of fasteners 50 a.
Extending forward from the top surface of the base wall 200 is the first forward wall 230. The first forward wall 230 extends forward at an angle to the base wall 200, preferably a right angle. Notably, the first forward wall 230 is offset from the distal edges 224 of the base wall 200 and runs substantially along the middle of the top surface 223 along the entire length of the base wall 200.
Extending from a free end 234 of the first forward wall 230 is the second wall 250. The second wall 250 preferably runs parallel to the axis of the base wall 220 or may be set off at a slight angle to the base wall 220, to accommodate a bend in a wall or external wall paneling 60. A second forward wall 240 extends from a free end 242 of the second wall 250. Preferably an H-rail 200 is comprised of two second forward walls 240 a and 240 b, each of the two forward walls 240 a and b extending forward and at an angle, preferably a right angle, from the second wall 250. A side wall 260 extends from a free end 244 of the second forward wall 240. The sidewall 260 is preferably parallel to the external paneling 60 and preferably also runs parallel to the base wall 220, although the sidewall 260 may be set off at an angle with respect to the orientation of the base wall 220 so as to accommodate form, shape or angle of a particular wall panel 60.
The two second forward walls 240 combine with the second wall 250 to form an inverted channel 352. The side walls 260 may extend away from the inverted channel 252 or over the inverted channel 252 and offer surface to fasten wall paneling 60 to the affixing rail 200 using a plurality of fasteners 50 b.
The section of the base wall 220 extending from the point of the first forward wall 230 and the distal end 224, in combination with the first forward wall 230, and the section of the first forward wall 230 extending from the free end 234 until the free end 242 of the second wall 250, form the first cavity 232 and the second cavity 233, with designations first or second cavities being entirely interchangeable. A distal end 65 of the insulating material 64 conveniently abuts the first forward wall 230 and can be retained within the first and second cavities 232 and 233 without further holding elements.
Still on FIG. 11 , the affixing rail 200 may be placed in an adjacent and spaced apart association with an edge rail 300. The edge rail 300 comprising a base wall 320. The base wall 320 having a top surface 323 and a bottom surface 323. The bottom surface 322 is mounted onto an existing wall 62. A first forward wall 330 extending forwardly from the free end 325, at an angle, preferably a right angle, from the top surface 323. A second wall 350 extending from a free end 324 of the first forward wall 330. It is preferable that the second wall 350 is oriented in the same direction as said base wall 320. A second forward wall 340 extends forwardly at an angle, preferably a right angle, from a free end 342 of the second wall 350. A side wall 360 extending sideways, at an angle from the free end 344 the second forward wall 340. It is preferable that the side wall 360 is oriented in the same direction as the second wall 350 and/or the base wall 320. A wall panel is then fastened to the sidewall 260 of the affixing rail 200 and the sidewall 360 using fasteners 50 b. The second wall 350 between the free end 324 and the free end 342. first forward wall 330 and the said top surface 323 forming a first 332 cavity. Thus, the space 75 between edge rail 300 and an adjacently mounting affixing rail 200 may contain a section of insulating material, where one end 65 of the insulating material 64 is held within the second cavity of 233 of the affixing rail 200 and the other end 65 is held within the first cavity 332 of the edge rail. To extend FIG. 11 , the adjacent affixing rail 200 will mount at a space 75 away from the affixing rail 200. And one end 65 will be held within the first cavity 232 of the affixing rail and the opposing end 65 of the insulating material 64 will be held in the second cavity 233 of the next or adjacent rail 200, until the entire wall surface 62 is covered with rails supporting insulation 64. The exterior wall panels 60 are then attached to the sidewalls 260 and 360 using fasteners 50 b.
The first forward walls 230 of the affixing rail 200 and first forward wall 330 of the edge rail 300, further comprise a retaining slot 27 which is preferably coaxial between the adjacent affixing rails 200 or between the adjacent affixing rail 200 and edge rail 300. The retaining slot 27 accommodates the pin sections 72 of the rod 100. The rod 100 represents a holding element which secures the insulating material within the space 75 and enforces the gap 67 between insulating material and the wall panel 60.
The two second forward walls 240 and the second wall 250 form an inverted channel 352. The channel may be relatively deep of substantially shallow as shown in FIG. 12 . Also visible in FIGS. 12 are multiple retaining slots 27 comprising of a lower retaining slot 27 a and the upper retaining slot 27 b. The retaining slot used depends on the thickness 69 of the insulating material 64. The gap 355 between individual wall panels 60 is a thermal expansion gap, which may contain a caulking or weatherstripping material. It should be noted that the pin sections identified throughout this application, for example the pin sections 72 a and 72 b are shown to be substantially planar. Alternatively, the pin sections may be angular, cylindrical or tubular.
FIGS. 13 is a detailed diagram of a perspective view of the shown affixing rail 200. Shown is the base wall 220, having the bottom surface 222 and the upper surface 223, the first forward wall 230 extending forwardly from the top surface 223. The first forward wall 230 may be perfectly perpendicular to or at an angle with respect to the axis of the base wall 220. The first forward wall 230 terminates at a second wall 250, which preferably is substantially parallel to the base wall 220. At least two second forward walls 240 extend forward and substantially on either edge of the second wall 250. The second forward walls 240 may extend straight up, or angle toward each other, like walls of a trapezoid, or flare away from each other. Furthermore, the second forward walls 240 may be elliptical. The second forward walls 240 may also be beveled sloping surfaces as shown in FIG. 12 .
The elevational diagram in FIG. 14 demonstrates a base wall 220. Issuing upward from the point 221 is the first forward wall 230. The sections of the base wall 220 between the point 221 and the distal ends 234 may be of equal or unequal lengths. Issuing from the free end 234 is the second wall 250 which extends laterally in two direction from the free end 234. It should be noted that the sections of the second wall 250 which cantilever from the free end 234 may be flat as shown, angular or elliptical. At least two second forward walls 240 extend forward from free ends 242, with a side wall 260 issuing from one or both free ends 244 in the direction away from the inverted channel 352. The outer surfaces 262 are used for mounting wall panels 60.
FIG. 15 is a sideview diagram of the affixing rail 200, showing the base wall 220, the first forward wall 230, the second forward wall 240 and the side wall 260. The first forward wall 230 further comprises a plurality of openings 28 for draining air or moisture. The openings 28 may be slots, holes or angular apertures, such as squares and triangles. The openings 28 may be on a diagonal or in a form of an arc, zigzag or wave. The openings 28 perforate the first forward wall 230 completely. Retaining slots 27 are shown to be co-axial with each other. The retaining slots may intersect or be incorporated into the openings 28 or exist independently from the opening 28. The retaining slots 27 may be elongated, elliptical, circular, coaxial with the length of the first forward wall 230, or the width of the first forward wall 230, or at an angle in between the length and width axis of the first forward wall 230, such as on a diagonal. The affixing rail 200 or the edge rail 300 is preferably made from thermally excluding materials, such as polymers, or composite materials, such as fiberglass, or other materials such as metal and wood.
FIG. 16 is a contextual diagram of the embodiment shown in FIGS. 11-14 . Shown are adjacent affixing rails 200, accommodating a second of insulating material 64 in the space 75. The insulating material is secured using a holding element 70, which is shown as a rod 100. The holding element 70 may be a peg 110 (FIG. 8 ) or a combination of rods 200 and pegs 110. While not shown, a wall panel(s) would then be affixed to sidewalls 260 using fasteners, cement, adhesive or some combination thereof.
The affixing rail described in FIGS. 11-16 may contain additional or fewer openings 28 than previously described. In one example shown in FIG. 17 , the affixing rail 200 is shown having the base wall 220, the first forward wall 230, the second wall 250, the two second forward walls 240 and the sidewalls 260. The first forward wall 230 contains openings 28. One or both of the second forward walls 240 comprise a plurality of openings 28 d. Stiff further openings 28 e are shown within the inverted channel 352. Additionally, the sidewalls 260 may contain a plurality of fastener access openings 28 f to more easily access and deploy fasteners 50 a along the section of the base wall 220 that overlaps with the sidewalls 260, during installation or removal of the affixing rail 200. While all openings 28, 28 d, 28 e and 28 f are shown in an oval shape with the length of the openings oriented in parallel to the length of the affixing rail 200, the orientation may be at an angle, such as 45° or 90° with respect to the length or at any angle therebetween. Furthermore openings 28, 28 d, 28 e and 28 f may be of any size and shape and may be co-axial or placed randomly along the respective walls comprising the affixing rail 200.
FIG. 18 is the sideview of the affixing rail 200 as shown in FIG. 17 . Shown are a plurality of air or moisture openings 28 b along the second forward wall 240 and at least one opening 28 along the first forward wall 240. Also clearly seen are retaining slots 27 having at least two co-axial levels 27 a and 27 b. Additional co-axial levels of retaining slots 27 may be disposed. Notably, in the embodiment shown in FIGS. 17 and 18 , the retaining slots 27 and the ventilation openings 28 do not intersect.
FIG. 19 is a closeup of the openings 28 e within the at least one inverted channel 352. The position of the openings 28 e places them above the insulating material within the first and second cavities 232 and 233. The same openings 28 e can serve as access points to reach the fasteners 50 a along the base wall 220. The layout is shown in context in FIG. 20 . Other fasteners my be placed along the edge 220 a of the base walls 220. Shown are a plurality of air or moisture openings 28 b along the second forward wall 240 and at least one opening 28 along the first forward wall 240. The pluraliclity of opeings 28 b will remain open whether the inulation material 64 is being held in place by the holding elements 70 or is simple wedged undernech the second wall 240 of the affixing rails 200. Both the openings 28 b and 28 e serve as air and water drainage openings and to provide a bit access for attaching the affixing rails using a plurality of fasteners 50 a.
FIG. 20 demonstrates to plurality of affixing rails 200 that are mounted onto a wall 62 using fasteners 50 a. The affixing rails 200 will be arranged as shown along the entire surface of the wall 62 as desired or as dictated by wall curvatures. An edge rail 300 (FIG. 11 ) mounted adjacently and in a spaced apart association to the nearest affixing rail 200 will frame an aperture in the wall, such as a door or window, or an interruption in the wall surface, such as a design or structural element, a corner or a bend. A plurality of openings 28 f and 28 e are intended to serve as air circulation and water drainage openings as well as a way to access fasterens 50 a. Other fastening means may include the use of welding or adhesives. The holding element 70 shown as a plurality of rods 100 is mounted across the gap 74 within retaining slots 27 of adjacent affixing rails 200 (or an affixing rail 200 and an adjacent edge component 300) or within the air openings 28.
Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention. While various inventive aspects, concepts and features, of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, devices and components, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Parameters identified as “approximate” or “about” a specified value are intended to include both the specified value and values within 10% of the specified value, unless expressly stated otherwise. Further, it is to be understood that the drawings accompanying the present disclosure may, but need not, be to scale, and therefore may be understood as teaching various ratios and proportions evident in the drawings. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described heroin without being expressly identified as such or as part of a specific invention, the inventions instead being set forth in the appended claims, as currently written or as amended or added in the future. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.

Claims

What is claimed is:

1. A system of securing wall panels unto an existing wall comprising: a plurality of affixing rails, each affixing rails of said plurality of affixing rails mounting onto an existing wall in an adjacently spaced apart association with at least one other of said plurality of affixing rails; wherein one of said plurality of affixing rails comprising of at least two first forward walls, wherein said at least two first forward walls being in a spaced apart orientation with each other; at least one base wall, said at least one base wall having a top side and a bottom side, said at least one base wall issuing at an angle from a first edge of at least one of said at least two first forward walls; wherein said bottom side configured be placed against said existing wall, and wherein said at least one base wall further configured to serve as an anchor point for attachment of each one of said plurality of affixing rails to said existing wall; a first forward wall, said first forward wall extending forwardly from said top side; wherein a second wall extending from a second edge of said at least two first walls, wherein said second wall spanning the space between said at least two first walls; wherein said first wall walls and said second wall forming a first channel; wherein said first channel configured to retain an insulating material; wherein a space between each two adjacent of said plurality of said affixing rails configured to retain an insulating material; and wherein said second wall configured to have a wall panel of a plurality of wall panels affixed thereto.

2. The system of securing wall panels unto an existing wall of claim 1, wherein said at least two first walls further comprising a plurality of retaining slots, wherein said plurality of retaining slots configured to removably contain a holding element.

3. The system of securing wall panels unto an existing wall of claim 2, wherein said plurality of retaining slots further configured to serve as openings for air ventilation and moisture drainage.

4. The system of securing wall panels unto an existing wall of claims 3, wherein said second wall further comprises at least one second channel.

5. The system of securing wall panels unto an existing wall of claim 4, wherein said a trough of said second channel impinging into said first channel.

6. The system of securing wall panels unto an existing wall of claim 5, wherein said plurality of holding slots are co-planar.

7. The system of securing wall panels unto an existing wall of claim 6, further comprising at least one additional plurality of holding slots, wherein said at least one additional plurality of holding slots is co-planar; and wherein each one of said at least one additional plurality of holding slots is configured to hold a holding element.

8. The system of securing wall panels unto an existing wall of claim 5, further comprising a plurality of air and moisture circulation openings, said plurality of air and moisture circulation openings disposed independently from said plurality of retaining slots.

9. The system of securing wall panels unto an existing wall of claim 2, wherein said holding element is a peg or a rod.

10. The system of securing wall panels unto an existing wall of claim 7, wherein said holding element is a peg or a rod.

11. The system of securing wall panels unto an existing wall of claim 8, wherein said holding element is a peg or a rod.

12. The system of securing wall panels unto an existing wall of claim 1, wherein said holding element further comprises a first section, said first section being inserted to one of said plurality of said holding slots and wherein said first section holding said insulating material within said first channel at a distance from said second wall.

13. The system of securing wall panels unto an existing wall of claim 5, wherein each of said plurality of affixing rails is made from thermally insulating materials.

14. A system of securing insulation and wall panels unto an existing wall comprising: a plurality of affixing rails, each affixing rails of said plurality of affixing rails mounting onto an existing wall in an adjacently spaced apart association with at least one other of said plurality of affixing rails; each of said plurality of affixing rails having a base wall said base wall having a top surface and a bottom surface, said bottom surface being attached to an existing wall; a first forward wall extending forwardly at an angle from said top surface, said first forward wall having a first side and a second side; a second wall attaching to a free end of said first forward wall; wherein said second wall having a front surface and a back surface; at least two second forward walls extending forwardly at an angle from said top surface, said at least two second forward walls being in a parallel and spaced apart configuration from each other; wherein said at least two second forward walls and said second wall forming an inverted channel; a side wall extending at an angle from a free end of each of said at least two second forward walls; wherein said side wall oriented in a direction opposite that of said second wall; wherein said top surface said either first side or said second side of said first forward wall and said bottom surface forming a first and second cavities; a space between two of said plurality of affixing rails configured to retain a length of an insulating material; wherein said second cavity of said affixing rail configured to retain an end of said insulating material and said first cavity of an adjacently mounted affixing rail configured to retain an opposing end of said insulating material; and wherein each of said side walls configured to have a wall panel fastened thereto.

15. The system of securing insulation and wall panels unto an existing wall of claim 14, wherein said plurality of affixing rails further comprises an edge rail, said edge rail having a base wall said base wall having a top surface and a bottom surface, said bottom surface configured to be mounted onto an existing wall; a first forward wall extending forwardly at an angle from said top surface; a second wall extending from a free end of said first forward wall, said second wall oriented in the same direction as said base wall; a second forward wall extending forwardly at an angle from a free end of said second wall; a side wall extending at an angle from a free end of said second forward wall; wherein said side wall oriented in the same direction as said second wall and said base wall; wherein said second wall said first forward wall and said top surface forming a first cavity; wherein a space between said edge rail and one of said plurality of affixing rails configured to retain a length of an insulating material; wherein a second cavity of said one of said plurality of affixing rails configured to retain an end of said insulating material and said first cavity of said edge rail configured to retain an opposing end of said insulating material; and wherein said wall of said edge rail configured to have a wall panel fastened thereto.

16. The system of securing insulation and wall panels unto an existing wall of claim 15, wherein said first forward wall further comprises a plurality of retaining slots wherein each of the retaining slots in said plurality of retaining slots is configured to hold a holding element, said holding element configured to hold a top surface of said insulating material below said second wall.

17. The system of securing insulation and wall panels unto an existing wall of claim 16, wherein said plurality of holding slots is further configured to train water and air ventilation.

18. The system of securing insulation and wall panels unto an existing wall of claim 15, further comprising a plurality of air and moisture circulation openings, said plurality of air and moisture circulation openings disposed independently from said plurality of retaining slots.

19. The system of securing insulation and wall panels unto an existing wall of claims 16, further comprising at least one additional plurality of holding slots, wherein said plurality of holding slots are co-planar, and wherein said at least one additional plurality of holding slots are co-planar.

20. The system of securing insulation and wall panels unto an existing wall of claim 15, wherein said holding element is a peg or a rod.

21. The system of securing insulation and wall panels unto an existing wall of claim 18, wherein said holding element is a peg or a rod; and wherein a first portion of said rod being inserted into a holding slot of one of said plurality of affixing rails and an opposite first portion of said rod being inserted into holding slot of an adjacently placed one of said one of said plurality of affixing rails or said edge rail.