Note: Descriptions are shown in the official language in which they were submitted.
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ARCHITECTURAL PANEL FABRICATION SYSTEM
BACKGROUND OF THE INVENTION
The present invention relates to a panel fabrication system
for attaching architectural wall panels to a building. In particular, the
present invention relates to a snap-fit assembly that assures proper
alignment of the panels, ease of installation arid lower fabrication and
installation costs.
For certain types of buildings, panels are often used to
cover the exterior walls of the building. The panels are used for
aesthetic purposes and can be economically beneficial to the owner.
Typically a single panel can be used to cover a large section of the
building. Fabrication or (framing) systems are commonly used to attach
panels (such as composite, aluminum, glass, stone, precast, etc.) to an
exterior surface or a support structure of a building. However, the
fabrication systems currently in use are expensive and require
considerable time and labor to install and fabricate.
Generally most fabrication systems for attaching panels to
a building support utilize a screw-on system or a compression fit system
requiring a screw. Systems utilizing screws and other fasteners add
labor costs because of additional time required for installation and
fabrication. Generally, after the panels are installed within the
fabrication system, a leveling and alignment process of the panels
occurs. The leveling and the alignment process further lengthens the
period of time required for proper installation. Furthermore, if the panel
needs to be removed due to damage, most fabrication systems require
the removal of numerous panels to replace the damaged one. This
results in increased maintenance costs for maintaining the fabrication
system.
Existing systems typically allow condensation to drain
down the panel and/or the building on which the panel is mounted. The
condensation drainage often leads to future leakage and other water
damage. Systems that use caulk as a sealant potentially leads to caulk
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migrating past the face of the panel. The caulk also absorbs
contaminants as it ages and causes discoloration and breaking down of
the caulk, thereby eliminating the aesthetic benefits of the fabrication
system. Dry set systems often fail due to improper panel alignment
which leads to future leakage within the framing system. Furthermore,
current systems use labor intensive methods to seal the corners of the
panel or bypass sealing the corners of the panels altogether. The labor
intensive methods of sealing lead to increased fabrication costs while
not sealing the panels lowers fabrication costs but leads to future
fabrication system failure.
Many fabrication systems utilize a multi-bracket
attachment system requiring the use of several different lengths of
brackets which have to be aligned at different locations along the
building support. This method increases both the labor costs for
engineering, fabrication and installation. Also, this method is quite
susceptible to misalignment, leading to the panels being installed in an
improper plane. Existing fabrication systems are often designed for use
with a specific type of panel. This limits the versatility of the fabrication
system and leads to increased costs if different types of panels are used
for a single structure. Most systems also utilize aluminum extrusions
which are not as resilient or cost effective as other alternatives.
The prior art systems for attaching a panel to a building
utilize methods that are labor intensive, have an inconsistency of quality,
and have higher maintenance and labor costs. Accordingly, a panel
fabrication system is needed in the art that is inexpensive and reduces
the time and ease of installation and fabrication. The prior art lacks a
framing system that is strong, maintains quality, insures proper panel
alignment and has low maintenance and labor costs.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to an extruded fabrication
system for mounting a structure to a member surface. The attachment
system includes an anchor attached to the surface. The anchor has a
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pair of sidewaNs extending substantially perpendicular therefrom. The
pair of sidewalls form an anchor channel and have one or more first
flanges formed on at least one of the sidewalls facing the anchor
channel. The attachment system also includes a panel frame having a
body. The body has at least one lateral surface extending substantially
perpendicularly and the body is inserted into the anchor channel. The
body has first and second sidewalls extending from the body. The first
and second sidewalls define a frame channel for receiving edge portion
of the structural member. At least one of the first and second sidewalls
has a serrated inner face facing the frame channel.
In one preferred embodiment of the present invention a
gasket is engaged to the second sidewall of the panel frame to form a
seal adjacent the structural member. The gasket includes a pair of
sidewalls extending substantially perpendicular therefrom. The pair of
sidewalls form a gasket channel. One or more third flanges are formed
on at least one of the sidewalls for engaging the second sidewall of the
panel frame.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further explained with
a
reference to the drawing figures listed below, wherein like structure is
referenced by like numerals throughout the several views.
FIG. 1 is a perspective view of a building using an
inventive panel fabrication system.
FIG. 2 is an exploded end view of an exemplary
embodiment of the fabrication system of the present invention.
FIG. 3 is a end view of an anchor used in the inventive
fabrication system of FIG. 2.
° FIG. 4 is a end view of a panel frame used in the inventive
fabrication system of FIG. 2.
FIG. 4A is an enlarged end view of a portion of the panel
frame taken from section 4A of FIG. 4.
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FIG. 5 is an assembled end view of the fabrication system
of FIG. 2.
FIG. 6 is an assembled end view of a second exemplary
embodiment of the fabrication system of the present invention.
FIG. 7A is a top view of a structural member 12 prior to
assembly.
FIG.7B is a perspective view of afolded structural member
for use in the inventive fabrication system.
While some of the above-identified figures set forth
preferred embodiments of the invention, other embodiments are also
contemplated, as noted in the discussion. In all cases, this disclosure
presents the invention by way of representation and not limitation. It
should be understood that numerous other modifications and
embodiments can be devised by those skilled in the art, which fall within
the scope and spirit of the principles of the invention.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of a building 10 using an
inventive fabrication system (not shown) to attach structural members
12 to the building 10. The building 10 has at least four support walls 14
and a roof 16. The structural members 12 are attached to the support
walls 14 of the building 10. In FIG. 1, the structural members 12 may
include composite panels 18, glass windows 20 or other ornamental or
functional building components. Also, brick 22 is mounted to the
building 10 at the corners. The building 10 is used as an example of a
building utilizing the inventive fabrication system. Those skilled in the
art will recognize that the present invention may be employed on
buildings of varying size and shape, as well as in connection with
different types of structural members, including composite, aluminum,
glass, stone, and precast. The structural members may be attached to
other surfaces on the building 10, including the support structure,
building support, or a generally vertical surface. Furthermore, the
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structural members may be attached to any structure, such as bridges
or vehicles, and can be used for other forms of construction assemblies.
FIG. 2 shows an exploded end view of an exemplary
embodiment of a fabrication system 24. The fabrication system 24
5 includes an anchor 26 (secured to a surface 27 of an underlying support
structure), at least one panel frame 28, a gasket 30,' and the structural
member 12. FIGs. 3 and 4 further illustrate the anchor 26 and the panel
frame 28, respectively. The anchor 26, the panel frame 28 and the
gasket 30 are preferably made of plastic and are formed by an extrusion
manufacturing technique. However, those skilled in the art will
recognize the fabrication system 24 can be extruded using a variety of
materials, for example, PVC, aluminum and steel, and the fabrication
system 24 is adaptable to be installed with different types of materials,
such as composite, glass, precast or eface.
The anchor 26 has a base plate 32. A first sidewall 34 and
a second sidewall 36 extend from the base plate 32 to form an anchor
channel 38. The sidewalls 34 and 36 lie subsfiantially perpendicular to
the base plate 32. The first sidewall 34 has an inner face 40 and the
second sidewall has an inner face 42. The inner faces 40 and 42 face
inward toward the anchor channel 38. First flanges 44 are formed on
one or both of the inner faces 40 and 42. The anchor channel 38
receives the panel frame 28. In the exemplary embodiment shown in
FIG. 2, two sets of first and second sidewalls 34 and 36 extend from the
base plate 32 to form two anchor channels 38. Although FIG. 2
illustrates two first flanges 44 formed on the sidewalls 34 and 36, those
skilled in the art will recognize any number of flanges can be formed on
the sidewall and that the flanges 44 can be formed on one or both
sidewalls.
The panel frame 28 includes a body 46, a first sidewall 48
and a second sidewall 50. The body 46 has a first end 52 and a second
end 54. The first end 52 is preferably tapered to form a neck 55
proximate the second end 54. A lateral surface 57 extends
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perpendicularly from the body 46 of the panel frame 28. One or more
second flanges 56 are formed adjacent the neck 55 such that the lateral
surface 57 is part of the second flanges 56. When the fabrication
system 24 is assembled, the body 46 of the panel frame 28 is inserted
into the anchor channel 38 of the anchor 26 and the lateral surface 57
of the second flanges 56 engages with the first flanges 44 of the anchor
26, thereby securing the panel 28 to the anchor 26 by mechanical
engagement. Those skilled in the art will recognize any number of
flanges may be formed along the length of the body of the panel frame.
The first sidewall 48 and the second sidewall 50 of the
panel frame 28 extend from the second end 54 of the body 46. The
sidewalls 48 and 50 preferably lie substantially parallel to the body 46.
Each sidewall has a first end 58, 59 and a second end 60, 61. The
sidewalls 48 and 50 form a frame channel 62. Preferably, the second
end 60 of the first sidewall 48 is further form the body 46 than the
second end 61 of the second sidewall 50. The first sidewall 48 has an
inner face 64 and the second sidewall 50 has an inner face 66 with the
innerfaces 64 and 66 facing inwardly toward the frame channel 62. The
inner faces 64 and 66 are serrated with a plurality of flanges 68, or
teeth, formed on the inner faces 64 and 66. The flanges 68 preferably
lie along the entire length of the sidewalls 48 and 50. When the
fabrication system 24 is assembled, the sfructural member 12 is inserted
into the frame channel 68 of the panel frame 28. The flanges 68 grip
the structural member 12 to hold the structural member 12 within the
frame channel 62. FIG. 4A shows an enlarged end view of the second
sidewall 50 of the panel frame 28 with the flanges 68 along the inner
face 66. Although FIG. 2 shows serration on the first and second
sidewalls 48 and 50, those skilled in the art will recognize the flanges 68
can be formed on one or both sidewalls.
As seen in FIG. 4, a panel flange 70 extends from the
second end 60 of the first sidewall 48. The panel flange 70 lies
substantially perpendicular to the first sidewall 48 and extends away
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from the frame channel 62. A gasket seat 72 extends from the second
end 61 of the second sidewall 50 and away from the frame channel 62.
The gasket seat 72 includes a shoulder 74, an upper arm 76 and a
lower arm 78. The shoulder 74 is attached to the second end 61 of the
second sidewall 50. The shoulder 74 extends away from the frame
channel 62 and lies substantially perpendicular to the second sidewall
50. A ledge 80 is formed on the shoulder 74. The upper arm 76 is
attached to the shoulder 74. The upper arm 76 extends away from the
body 46 and lies substantially parallel to the first sidewall 48. The lower
arm 78 is attached to the upper arm 76. The lower arm 78 extends at
an acute angle from the upper arm 76 towards the second end 60 of the
first sidewall 48.
As seen in FiG. 2, the gasket 30 includes a base plate 82,
a first sidewall 84 and a second sidewall 86. The first sidewall 84 is
attached one end of the base plate 82. The first sidewall 84 extends
from the base plate 82 and lies substantially perpendicular to the base
plate 82. The second sidewall 86 is attached to the base plate 82. The
second sidewall 86 extends from the base plate 82 and lies substantially
perpendicular to the base plate 82. The first and second sidewall 84
and 86 form a gasket channel 90. In the exemplary embodiment of the
fabrication system 24 shown in FIG. 2, two sets of first and second
sidewalls 84 and 86 extend from the base plate 82 to form two gasket
channels 90.
The first sidewall 84 has an inner face 92 and the second
sidewall 86 has an inner face 94. The inner faces 92 and 94 face
inward towards the gasket channel 90. The first sidewall 84 has an end
96 opposite the base plate 82 and the end 96 is tapered. The second
sidewall 86 has an end 98 opposite the base plate 82 and the end 98 is
tapered. A third flange 100 extends from the end 98 of the second
sidewall 86 towards the gasket channel 90. Preferably, the second
sidewall 86 has a height greater than a height of the first sidewall 84.
When the fabrication system 24 is assembled, the third flange 100 of
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the gasket channel 90 engages the gasket seat 72 of the panel frame
28.
Preferably, the structural member 12 has a body 102 and
at least one support edge 104 (see FIG. 2). The structural member 12
is preferably a composite panel. However, two different types of panels
may be used within one fabrication system. For example, the structural
member 12A may be aluminum and the structural member 12B may be
glass. The support edge 104 of the structural member 12 extends from
one end of the body 102 and has an inner face 103. The support edge
104 lies substantially perpendicular to the body 102. The support edge
104 has a length. Preferably, the length of the frame channel 62 is the
same. Once the fabrication system 24 is assembled, the support edge
104 of the structural member 12 is inserted into the frame channel 62.
The flanges 68 of the pane! frame 28 grip the support edge 104 to hold
the structural member 12 in place. An end 105 of the support edge 104
abuts a bottom 63 of the frame channel 62.
Those skilled in the art will recognize that other means
may be used to secure the structural member 12 within the frame
channel 62 of the panel frame 28. For example, a connector or adapter
may replace the support edge 104. The connecter is attached to the
body of the structural member and the connecter is inserted into the
frame channel and gripped by the flanges to hold the structural member
in place.
FIG. 5 is an assembled end view of the fabrication system
24. The anchor 26 is attached to a building support 106 of the building
10. The anchor 26 can be attached to the building support 706 either
horizontally or vertically so that once the structural members 12 are
attached, the structural members 12 run horizontally or vertically. A
fastener 108 (such as a screw, bolt, rivet, etc.) is used to attach the
base plate 32 of the anchor 26 to the building support 106. An adhesive
110 is used in the exemplary embodiment around the fastener 108 to
help secure the anchor 26 to the building support 106. Those skilled in
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the art will recognize the fabrication system 24 can be attached in other
ways, and to other surfaces such as the exterior wall of the building or
any vertical surface.
One panel frame 28 is secured within each anchor channel
38. The body 46 of the panel frame 28 is inserted into the anchor
channel 38. The first flanges 44 of the anchor 26 engage the lateral
surface 57 of the second flanges 56 of the body 46 to secure the panel
frame 28 within the anchor channel 38. An adhesive 112, preferably a
silicone bead, is deposited within the anchor channel 38 to help the
panel frame 28 to anchor 26.
The frame channel 62 receives the support edge 104 of
the structural member 12. The flanges 68 of the sidewalls 48 and 50
grip the structural member 12 to secure the structural member 12 within
the frame channel 62. Once the structural member 12 is secured within
the frame channel 62, the inner face 64 of the panel frame 28 abuts the
inner face 103 of the edge 104 of the structural member 12. In the
exemplary embodiment shown in FIG. 5, two adjacent panel frames 28
are mounted, although other embodiments exist for the anchor allowing
any number of panel frames to be used. Preferably, the two structural
members 12 secured by the panel frames 28 extend in opposite
directions. ,
The gasket 30 is preferably used in the fabrication system
24 when the anchor 26 has at least two anchor channels 38 securing
two panel frames 28. The second sidewalk 50 of the two panel frames
28 face each other. The gasket 30 is attached to the gasket seat 72 on
each second sidewail 50. The gasket channels 90 of the gasket 30
engage the ledge 80 of the gasket seat 72 on the panel frame 28. The
third flange 100 on the second sidewall 86 engages the ledge 80 of the
gasket seat 72. The gasket seat 72 is secured within the gasket
channel 90 to secure the gasket 30 to the panel frame 28. An adhesive,
preferably a silicone bead, is placed in each gasket channel 90 to help
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secure the gasket 30 to the panel frame 28 and create a moisture seal
adjacent the structural members.
As seen in FiG. 5, The assembled fabrication system 24
forms an inner cavity 116. The cavity 116 is formed by the base plate
5 32 of the anchor 26, the second sidewalls 36 of the anchor 26, the
second sidewalls 50 of the panel frame 28, the second sidewalls 86 of
the gasket 30 and the base plate 82 of the gasket 30. Condensation
which may collect under the structural members 12 travels through the
cavity 116. The cavity 116 prevents moisture and condensation from
10 traveling along the front or the rear of the structural members 12.
FIG. 6 is an assembled end view of another exemplary
embodiment of an inventive fabrication system 200. The fabrication
system 200 is used in conjunction with the coupling of different facade
or structural materials, such as a panel system and a window wall
system 202. The window wall system 202 preferably holds a glass wall
204 and attaches to the support wall 14 of the building 10. Although the
window wall system 202 is used as an example in FIG. 6, those skilled
in the art will recognize that other structural members may be used in
conjunction with the fabrication system 200.
The fabrication system 200 includes an anchor 226, the
panel frame 28 and the structural member 12. The anchor 226 has one
anchor channel 238 formed by the first and second sidewalls 234 and
236. The body 46 of the panel frame 28 is inserted into the anchor
channel 238 and snap-fit into position. The support edge 104 of the
structural member 12 is secured within the frame channel 62.
Preferably, a single structural member 12 is used in the fabrication
system 200, with the anchor 226 attached as discussed above.
Once the fabrication system 200 is assembled, the
fabrication system is attached to the window wall system 202. An
adhesive ball 206 secures the window wall system 202 to the fabrication
system 200. In the exemplary embodiment, the windowwall system 202
is attached to the second sidewall 50 of the panel frame 28. Caulk 208
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is used to provide a moisture seal between the fabrication system 200
and the window wall system 202. A weep hole 210 is formed in the
fabrication system 200 and provides a gutter system to prevent the
drainage of condensation on the face of the structural member 12. The
weep hole extends through the first sid,ewall 48 of the panel frame 28
and the support edge 104 of the panel 12. A screen 212 is placed over
one end of the weep hole 210 to prevent insects or other debris from
passing through the weep hole 210.
FIG. 7A is a top view of the structural member 12 in a flat
position. One process for forming the structural member having the
body 102 and at least one support edge 104 is a folding method to
create an envelope pan corner. A notch 214 is formed along one edge
of the structural member 12 proximate a corner of the structural member
between a first edge 216 and a second edge 218. The notch is
preferably triangular shaped.
FIG. 7B shows a folded structural member 12 forming an
envelope pan corner 220. Both edges 216 and 218 are folded
substantially 90 degrees to form the support edge 104. The ends of
each edge meet to form a seam 222 along one support edge 104.
Moving the seam 222 of the structural member 12 from the corners of
the structural member provides greater strength, and results in less
likelihood of water penetration and a sharper profile at the corners. In
addition, a plate 224 may be fastened to the support edge 104 with a
fastener 226 (preferably a rivot). The plate provides support and
strength and prevents water penetration. Once the structural member
12 is folded, the support edge 104 is inserted into the frame channel 62
of the pane! frame 28.
The fabrication system of the present invention insures
proper alignment of structural members on a building. The anchor is
preferably pre-located and pre-positioned on the building prior to
assembling the fabrication system and inserting the structural member.
Pre-positioning ensures proper location of the anchor, and thus of the
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fabrication system, prior to panel installation. Since the structural
members are secured to the panel frames, no post-assembly alignment
is necessary. The use of the panel frame set within the anchor provides
a properly positioned frame channel for receiving the structural member.
Once the structural members are inserted within the frame channel of
the panel frame the corners of the panel are automatically aligned and
the panel is square on the building. The panel flange provides another
means for insuring the structural member is properly aligned within the
panel frame. The snap-fit assembled fabrication system ensures proper
plane of the structural member once assembled and mounted to the
building. Pre-location of the anchor reduces installation time and labor
costs.
The use of flanges within the anchor channel and the
gasket channel, including the serrated frame channel, allows the
fabrication system parts to be snap-fit into position. The components of
the fabrication system do not require pop rivets or screws, a backup
plate, an attachment bracket or drill holes to assemble the fabrication
system. The flanged channels eliminate the requirement for multi-sized
panel clips and mechanical screw fasteners, thereby allowing easy and
quick installation to reduce labor time and costs. The flanged channels
provide non-mechanically applied snap-in connection between the
components of the fabrication system, in particular the panel frame and
the anchor.
The length of the anchor channel and the length of the
panel frame can be adjusted to meet various installation requirements
e.g., may be as long as edge support of structural member.
Furthermore, the anchor, the panel frame and the gasket of the
fabrication system may have a length that runs the entire height of the
building or the structural member such that a single fabrication system
is used for each structural member. Or multiple anchors, panel frames
and gaskets running the entire building may be used to attach a single
structural member of the building.
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The gasket seat of the panel frame provides a proper lock
to prevent migration of the gasket. The gasket provides a moisture seal
for the fabrication system. In particular, the cavity allows an area for
moisture and condensation to travel without traveling along the panel or
the building. The cavity acts as a buffer system for moisture to be
contained within the cavity and not on the face of the panel or the
building. This eliminates any discoloring on the panel surface due to
exterior drainage. The gasket is preferably formed from a flexible
material (e.g., silicone) and can thus be rolled into place and snap-fit
into position within the fabrication system. The gasket clips onto its
respective gasket seat and locks into place. The ability to quickly install
the gasket reduces labor costs at the time of installation and speeds up
the installation process. The adhesive is applied within the gasket
channel to provide further adhesion and act as a sealant. The gasket
and the adhesive further provide improved and proper adhesive seal
control. The use of the gasket and the adhesive in combination keeps
the gasket in position and eliminates discoloring problems due to
pollutants and migration of moisture past the face of the structural
member. The adhesive applied within the anchor channel also provides
a moisture seal.
The anchor and panel frame of the fabrication system are
preferably made of a high density PVC. The PVC material allows for
more resiliency and flexibility of the fabrication system. The fabrication
system will absorb the stress~due to expansion and contraction off the
panel joints. Thus, pillowing and/or buckling of the surface of the
structural member will be reduced. In addition, the PVC material is
lighter than aluminum, thus reducing the weight of the fabrication
system. The high density PVC material provides high impact resistence,
proper thermal break, resiliency for locking positions and prevents
bowing at the panel face.
A significant advantage of the inventive fabrication system
is a damaged panel may be removed individually. The ability to remove
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panels or individually from the fabrication system reduces maintenance
costs for the building. Overall, the ease of installation at a construction
site allows for reduced labor and quicker installation times. Also,
potential damage to panels may be reduced because lengthy storage
on site is no longer necessary.
Although the present invention has been described with
reference to preferred embodiments, workers skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention.
