Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
DUAL GLAZING PANEL SYSTEM
FIELD OF THE INVENTION
100021 Embodiments pertain to modular upstanding seam flange glazing panels
and other
glazing panels for architectural structures and, more particularly, to systems
for assembling
such modular upstanding seam flange panels and other panels into unique paired
glazing
panel units having an airspace between the panels and the ability to
efficiently limit air,
water and sound infiltration, to perform well under substantial positive and
negative panel
loads and significant ambient temperature changes, and to methods for
attaching the panel
units together and installing the units in sloped glazing, skylights, roofs,
walls, and other
architectural structures in ways not heretofore possible, including in curved
or radiused
structural configurations, and to new systems for supporting and attaching the
panel units to
supporting members.
BACKGROUND
[0003] Extruded modular panels with an internal honeycomb structure and
upstanding
seam flanges as well as generally flat panels made of polyearbonate and other
resins
including fiberglas are widely used in the design of various architectural
structures because
they are a strong, lightweight alternative to traditional materials, like
glass, which they often
replace. For example, current modular glazing panels can be joined along flat
panel edges or
along unitary upstanding seam flanges that extend along their opposite lateral
edges to form
glazing panel units that can be used either alone or with a supporting
framework of, e.g.,
purlins or rafters, to form overhead, wall, or roofing structures. The ability
of such panel
units to transmit light has made them particularly useful where it is desired
to allow sunlight
to pass into a structure such as to illuminate an interior region of a
building. An additional
advantage of these panel units is that they have good energy conservation and
sound
insulation characteristics. The glazing panel units also have greater
structural strength than
- 1 -
CA 2885428 2018-10-18
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
single panels making them useful in applications where single panels could not
be used or
would require additional supporting structural elements.
[0004] The current extruded modular panels with unitary upstanding seam
flanges as well
as generally flat panels made of polycarbonate and other resins maybe, e.g.,
up to 45 feet in
length, 2-6 feet wide and typically are flexible. It therefore requires
substantial skill and is
time-consuming to assemble and install the panels into glazing panel units on-
site. The
challenge to assembling and installing the panel units faced by such skilled
workers can be
appreciated, for example, by examining Figures lA and 1B which illustrate
representative
prior art panel pair assembly systems.
[0005] More particularly, Figure lA shows a puffin 1 and one of a series of
metal
retaining clips 2 spaced and affixed along the purlin. The retaining clips
include horizontal
upstanding flanges 3. Once the series of spaced retaining clips are in place
on the purlin (or
other supporting member), polycarbonate (or other resin) bottom modular panels
4A and 4B
are manipulated into position and slid horizontally under the flanges of the
retaining clips.
Then, an elongated resilient batten joint connector 5 with a downwardly facing
elongated
bottom cavity GA is forced down over the adjacent unitary upstanding seam
flanges 7A and
7B of modular panels 4A and 4B to lock them onto the retaining clips by way of
sawteeth in
the bottom cavity that mate with sawteeth on the adjacent pair of unitary
flanges of the
bottom panels. Finally, top modular panels 8A and 8B are manipulated into
position with
their seam flanges 9A and 9B aligned with the upwardly facing elongated top
cavity 6B in the
batten joining connector and pressed into place with the sawteeth of flanges
9A and 9B of
modular panels 8A and 8B held in place by corresponding sawteeth within cavity
6B.
[0006] Figure 1B shows juxtaposed panel units (or "insulated translucent
sandwich
panels") 11 each comprising top and bottom generally flat fiberglas panels 13
and 15 with a
grid made of up of vertically and/or horizontally disposed metal or resin grid
members 19
(only one shown) located in the space between the panels and in abutment with
the panels.
The grid serves to, inter alia, maintain the spacing between the panels. The
"fiberglas" from
which panels 13 and 15 are made is a fiber-reinforced polymer made of a resin
matrix
reinforced by glass fibers. The resin used in the fiberglas may be a
polyester, an epoxy, a
thermosetting plastic or thermoplastic. Shelf supports 21 located at the top
and bottom of the
grid members are affixed to panels 13 and 15 by adhesive which is located in
the interstices
between the shelf members and the inner faces 23 and 25 of the top and bottom
panels to
form glazing panel units. Finally, adjacent insulated sandwich panel units are
laterally
attached using a clamp 27 comprising a bottom support 29 and a top support 31.
In order to
lock the adjacent sandwich panel units together, a screw 33 is passed through
the bottom
- 2 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
clamp support and screwed home in a receptacle 35 that projects downwardly
from the top
clamp support to lock down the clamp. The attachment of the grid to the panels
as well as the
onsite lateral attachment of adjacent sandwich panels, as in the case of the
modular panels of
Figure 1A, is time-consuming and requires substantial skill.
[0007] While there are many known variations on the prior art panel unit
systems of
Figures lA and 1B, they are indicative of the relative complexity of
assembling and installing
paired panel units on-site to provide sloped glazing, skylights, roofs, walls
and other
architectural structures.
[0008] The system of Figure lA also illustrates the conventional metal
(retaining clip) to
resin skin (flange of panel) contact employed in current modular upstanding
seam panel
retention systems. Because those skilled in this art have been wed to fixing
the panels in
place through such direct engagement of an unforgiving hard or high ultimate
tensile strength
metal retention clip against the resilient low ultimate tensile strength
resin skin of the
polycarbonate modular panel, it has been necessary to take extra steps to
ensure that load
specifications are met. For example, skin weight of modular panel flanges is
greater than it
otherwise would need to be in order to prevent cracking of the polycarbonate
or other resin
skin of the panel flanges under load. This excess weight results in
unnecessary material
usage/cost and reduced light transmission. Also, large numbers of closely
spaced retention
clips are often required to meet wind load and other load specifications by
spreading out the
load across more clips also to prevent cracking of the resin skin of the
flanges under load,
again leading to increased weight and material, and labor waste.
[0009] Figure 1C illustrates a prior art system which does not entail the
use of prior
assembled modular panel units. Rather, lower panels 711 are fixed in place at
the desired
installation site after which spacers 712 are applied to the adjacent unitary
panel flanges of
the lower panels and top panels 713 attached to the spacers. Most
significantly, locking clips
714 must be located between the lower panels at regular intervals along the
panels. Since the
system does not include an armoring or cladding feature, support members to
which the clips
are attached must be positioned at relatively close intervals to receive
fasteners in the clips
and support the panels.
[0010] There is therefore a great need for a system that makes it easier
and less time-
consuming to assemble and install or erect glazing panel units by redesigning
the devices
used to attach opposed panels into panel units and to attach adjacent panel
units to support
members. For panel units with upstanding seam flanges, there is also a need
for
- 3 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
embodiments that improve the seam flange design, to enhance the overall flange
strength, and
to further streamline the process of attaching opposed panels into panel
units.
[0011] If such systems also provided a completed architectural glazing
structure
comprised of glazing panel units made up of modular upstanding seam flange
panels of the
current design or of an improved dual seam flange design, or of flat resin
panels, which is
safe, secure, strong and able to withstand substantially increased negative
and positive wind
and snow loads, a particularly unexpected and useful contribution to the art
would be at hand.
If embodiments of such systems further eliminated the inherent limitations of
conventional
metal-to-resin engagement, required fewer retention clips, and made it
possible to reduce
panel thickness, an extremely important and unexpected advance in the art
would be in the
offing.
[0012] Present embodiments provide systems for readily assembling pairs of
such glazing
panels into glazing panel units either on-site (but typically in convenient
ground level work
areas) or off-site, and then readily installing the pre-assembled panel units
on-site to erect the
sloped glazing, skylights, roofs, walls, and other architectural structures.
[0013[ Embodiments of these new systems are particularly elegant in that
they provide
unique panel engagement members that armor or metal clad the standing seams of
the
modular panels and the flat panel edges to thereby provide a unique new
retention that
withstands increased wind and snow loads while making it possible to reduce
the thickness
and weight of the flat panels or the resin skin of the flanges of the modular
panels and
optionally to use thinner and lighter bottom or inner panels. Embodiments also
provide
improved dual panel seam flange designs and corresponding further unique
attachment
members.
[0014] Embodiments of these new systems are also surprisingly economical in
terms of
materials (e.g., the number of retention clips can be reduced and modular
panels with thinner
and hence less expensive resin skins and thinner flat resin panels can be
used) and in terms of
construction costs since they can be erected quickly and generally without
special skills, and
produce architectural structures that can accommodate longer spans, are
surprisingly effective
in limiting air, water and sound infiltration, and have outstanding energy
conservation
characteristics. Indeed, the present systems make it possible to readily
insert infill into the
airspace between the panels off-site (or on-site) in the form of translucent
insulation (e.g.,
glass fiber), or to add metal screening to flat panel glazing units enhancing
the fire resistance
of the panel units and helping to resist severe localized impacts on the outer
panels of the
- 4 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
units. This is another welcome improvement since it is extremely difficult and
expensive to
add infill or metal grids to prior art panel units which must be assembled on-
site.
[0015] Finally, it is important to accommodate horizontal expansion and
contraction of
the glazing panel units under the typically widely varying ambient
temperatures to which the
panel units are subjected after they are installed. While prior systems for
assembling and
installing panel pairs have a limited ability to accommodate such expansion
and contraction,
the use of the various interlocking first and second locking engagement member
of
embodiments accommodate such horizontal expansion and contraction far better
than earlier
designs and in a way not contemplated by those skilled in this art.
SUMMARY
[0016] Embodiment comprises modular upstanding seam flange glazing panel
units.
These include panel units with opposed transparent or translucent elongated
top and bottom
modular upstanding seam flange panels with corresponding elongated upwardly
and
downwardly directed unitary flanges and an airspace between the panels. The
unitary seam
flanges are disposed at or near opposite lateral edges of the modular panels.
Interlocking first
and second locking engagement member designs are provided, including
embodiments
having upwardly and downwardly disposed cavities for receiving and retaining
corresponding
upwardly and downwardly directed flanges of the panels. The panel flanges may
each have
sawteeth and the cavities of the interlocking first and second locking
engagement members
may have corresponding sawteeth that engage and lock onto the panel flanges.
[0017] In other embodiments new extruded modular panels are provided with
dual seam
flanges at or near the lateral panel edges and corresponding first and second
locking
engagement members. The engagement members include latching members with
sawtooth
structures that are received into a cavity between the dual seam flanges to
lock the dual
flanges of opposing panels together to form panel units.
[0018] In still other embodiments, glazing panel units are provided
comprising opposed
transparent or translucent generally flat rosin panels. Corresponding first
and second locking
engagement members are applied along the lateral edges of each of the resin
panels either
with adhesive or in a press-fit structure that captures and armors or metal
clads the lateral
edges of the resin panels. As a result, the panel units can be aligned
laterally so that the
corresponding first and second locking engagement members can be interlocked
on-site in a
convenient and secure manner.
- 5 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
[0019] When two glazing panel units are generally aligned next to each
other and
interlocked, first and second locking engagement member embodiments of the two
adjoining
interlocked panel units may form an air cavity and an internal gutter for
collecting and
draining away water that infiltrates past the opposed lateral edges of the
panel units to
enhance moisture management of the system. In embodiments, a guide member
projects
from a first locking engagement member and is received in a walled cavity in a
second
locking engagement member. Also, preferably in embodiments either the second
locking
engagement member, the first locking engagement member, or both may include
one or more
resilient members sized and positioned to sealingly engage the guide member,
other selected
portions of the locking engagement members, or selected areas along the seam
flanges when
the first and second engagement members of the adjacent panel units are
interlocked.
[0020] In other embodiments, a first locking engagement member may include
a guide
member having a generally downwardly directed nub and a second locking
engagement
member includes a walled cavity for receiving the guide member with a
corresponding
generally upwardly directed nub on a wall of the cavity. The upwardly directed
nub on the
wall of the cavity is positioned to engage the nub on the guide member as the
first and second
locking engagement members are moved into interlocking position.
[0021] Other embodiments comprise architectural structures for passing
sunlight into
interior regions of a building while limiting the infiltration of water, air
and sound. At least
two transparent or translucent glazing panel units are provided comprising
either opposed top
and bottom modular panels with corresponding elongated upwardly and downwardly
directed
unitary or dual flanges or flat panels made of polycarbonate and other resins
and an airspace
between the panels. Interlocking first and second locking engagement members
are disposed
respectively at the opposite modular panel flanges or at the lateral edges of
the flat panels and
attached to supporting structure.
[0022] In embodiments, the modular panel skins and flat panels have
substantially lower
ultimate tensile strength than the ultimate tensile strength of interlocking
first and second
locking engagement members embodiments. This may be achieved by forming the
interlocking first and second locking engagement members from metal.
Alternatively,
however, the interlocking first and second locking engagement members may be
made of
other higher tensile strength materials such as an engineering plastic like
acrylonitrile
butadiene styrene (ABS), or of pultruded fiberglas or metal plast. The clips
used with
interlocking first and second locking engagement members may be themselves
made of metal
or of such higher tensile strength materials.
- 6 -
CA 02885428 2015-03-18
WO 2014/047466
PCT/US2013/060974
[0023] In erecting a panel unit structure, a first panel unit having a
first locking
engagement member is disposed opposite the corresponding second locking
engagement
member of a second panel unit and the engagement members are interlocked.
Preferably at
least one of the corresponding locking engagement members is first affixed to
a supporting
structure by retaining clips. Embodiments also include retaining clip and
locking
engagement member designs in which the clips are not present at the interstice
between
adjacent panel units. For example, clips may not be present in installations
that do not
require internal support and panel unit retention is provided by perimeter
framing.
[0024] In other embodiments the modular panels include resilient areas
along their lateral
edges. When such modular panels are installed, the resilient areas accommodate
lateral
expansion and contraction of the panels in conjunction with the interlocking
locking
engagement members and also help control air, water and sound infiltration.
Additionally, as
the resilient areas along the panel edges flex or compress laterally this
helps to reduce or
avoid buckling of the panels as a result of lateral panel expansion beyond the
point of contact
between the resilient edges of adjacent panels. Finally, it should be noted
that modular
panels with such resilient areas, along their lateral edges may be paired with
panels with rigid
lateral edges.
[0025] Other embodiments comprise methods of erecting architectural
structures for
passing sunlight into an interior region of a building while limiting the
infiltration of water,
air and sound. The methods include assembling together transparent or
translucent modular
panels having opposed elongated top and bottom unitary or dual upstanding seam
flanges
with corresponding elongated upwardly and downwardly directed flanges or flat
panel edges
and an airspace disposed between the panels into panel units. When modular
panels with
unitary or dual seam flanges disposed at or near opposite lateral edges of the
panels are used,
interlocking first and second locking engagement members each having upwardly
and
downwardly disposed cavities or upwardly and downwardly directed latch members
are
attached respectively to the corresponding upwardly and downwardly directed
unitary or dual
flanges of the modular panels. Finally, for both modular and flat panel units
the
corresponding first and second locking engagement members are interlocked or
interconnected to complete the architectural structure. In a preferred
embodiment, at least
one of the corresponding first and second locking engagement members is
affixed to the
supporting structure.
[0026] Finally, locking engagement member embodiments are provided in which
the
locking engagement members may be interconnected at varying angles with
respect to each
other to enable the erection of radiused or curved panel unit structures.
- 7 -
[026a] In a broad aspect, the present invention relates to a pair of
engagement members
for forming a panel unit assembly comprising: first and second engagement
members having
opposed panel-attachment members for retaining portions of opposed transparent
or
translucent panels; the first engagement member having a first wall disposed
between its
opposed panel-attachment members and a male member projecting from the first
wall; and
the second engagement member having a second wall disposed between its opposed
panel-
attachment members and a pair of sidewalls defining an interlock cavity for
receiving the
male member, characterized by: the male member including at least one catch
rail; the male
member including guide and pivot support rails which project from opposite
sides of the
male member proximal to the at least one catch rail and are dimensioned to
abut the inner
surfaces of the cavity sidewalls; and the at least one catch rail being
disposed on the male
member to engage an inner surface of a sidewal I of the interlock cavity of
the second
engagement member to limit pivoting movement between first and second
engagement
members when they are engaged.
[026b1 In another broad aspect, the present invention relates to a panel
unit assembly
comprising: first and second engagement members comprising a pair of
engagement
members according to the present invention, which are interlocked; and two
pairs of opposed
transparent or translucent panels with retaining portions attached to the
panel-attachment
members of the first and second engagement members forming adjacent
interlocked panel
units.
- 7a -
CA 2885428 2019-12-17
CA 02885428 2015-03-18
WO 2014/047466
PCT/US2013/060974
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] In order to aid in understanding the invention, it will now be
described in
exemplary embodiments it will now be described with reference to the
accompanying
drawings in which like numerical designations will be given to like features
with reference to
the accompanying drawings wherein:
[0028] Figures IA and 1B are a partial exploded perspective views of prior
art flat and
modular panel pair assembly and installation system;
[0029] Figure IC is a prior art system that does not include the metal
armoring or
cladding feature of the present invention:
[0030] Figure 2 is a sectional view of a portion of a modular upstanding
seam flange
panel;
[0031] Figures 3A and 3B are elevation views taken respectively at ends of
first and
second locking engagement members before and after they are interlocked;
[0032] Figures 4A and 4B respectively correspond to Figures 3A and 3B but
modular
panels are shown installed in the first and second locking engagement members
of adjoining
panel units;
[0033] Figures 5A and 5B correspond generally to Figures 4A and 4B except
that
alternative first and second locking engagement members are depicted in panel
units with an
enlarged airspace between the top and bottom panels;
[0034] Figure 6 corresponds to Figure 5B except that yet another
interlocking first and
second locking engagement member design is used in which the locking
engagement
members are provided with side stiffener bars,
[0035] Figure 7 is a partial exploded perspective view of an alternative
modular panel
design;
[0036] Figures 8A and 8B are, respectively, partial elevation views of
panel units using
still other locking engagement member designs with the modular panels of
Figures 7 in place
in the engagement members, before and after interconnection of the engagement
members;
- 8 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
[0037] Figure 9 is a partial elevation view of the tops of adjacent panel
units in which a
gasket is disposed in the gap between the adjacent top panels and held in
place by a pin
affixed to one of the locking engagement members of the units;
[0038] Figure 10 is partial elevation view of modular glazing panels in
which first and
second locking engagement members have gaskets to enhance sealing at the
interface
between adjacent panel ends of the modular panel unit;
[0039] Figures 11A and 11B are elevation views taken respectively at the
ends of yet
another embodiment of first and second locking engagement members;
[0040] Figure 12A is a perspective view of a clip member intended to be
used with the
locking engagement members of Figures 11A and 11B;
[0041] Figures 12B and 12C are partial elevation views showing the clip of
Figure 12A
affixed to the engagement members of Figures 11A and 11B;
[0042] Figure 13 is a partial elevation view of a vertical opening with a
support frame
into which glazing panel units are installed;
[0043] Figure 14 is an elevation view of a sill frame which may be used in
the support
frame of Figure 13;
[0044] Figure 15 is a side elevation view illustrating the attachment of
the sill frame of
Figure 14 to a structural support member of the frame of Figure 13;
[0045] Figure 16 is a partial elevation view of adjacent modular panel
units affixed in a
curved or radiused configuration;
[0046] Figure 17 is another partial elevation view of adjacent modular
panel units affixed
in a radiused or curved configuration;
[0047] Figure 18 is a partial elevation view of adjacent modular panel
units in which a
radiused configuration is achieved by inserting a spacer member between the
top panels of
the adjacent panel units;
[0048] Figure 19 is a partial elevation view of modular panel units mounted
in
interlocked hermaphroditic locking engagement members;
- 9 -
[0049] Figure 20A and 20B are partial elevation views of interlocked
modular panel units
where the locking engagement members holding the panel units include rigid
elongated
members or extensions which improve the rigidity and moment of inertia of the
panel units;
[0050] Figure 21 is a partial side elevation view of single modular panels
mounted in
interlocking members having interlocking strengthening extensions;
[0051] Figures 22A ¨ 22C are partial side elevation views of modular panel
units in which
a first locking engagement member includes a male member with catch rails
designed to
engage one of the opposing walls of the female member of the corresponding
locking
engagement member as necessary to prevent disengagement (Figure 22B) between
the locking
engagement members when excessive wind or snow loads are applied to the panel
units;
[0051a] Figure 23 is a detail view of the central portion of the arrangement
shown in Figure
22C;
[0052] Figures 23A and 23B are, respectively, partial perspective and
partial side elevation
views showing an alternative retaining clip design that maintains a
predetermined spacing
between the lower panels of interlocked panel units and a supporting member;
[0053] Figure 24 depicts fiberglas sandwich panels in a partial side
elevation view fitted to
a pair of locking engagement members prior to engagement of the locking
engagement
members;
[0054] Figure 25 is a partial side elevation view of a pair of laterally
disposed sandwich
panels with an alternative locking engagement members design that includes,
inter alia,
gaskcting;
[0055] Figure 26 depicts the sandwich panels and locking engagement members of
Figure
25 after the adjacent panels are interlocked and clipped in place;
[0056] Figure 27A and 27B are partial side elevation views of other modular
panel unit
embodiments utilizing modular panels with a dual flange design;
[0057] Figure 27C is a partial side elevation view of an alternate modular
panel dual flange
design in which both the distal ends of the panels of panel units and distal
portions of the
outer flanges are structured to have enhanced flexure and resilience;
[0058] Figure 28 is a partial side elevation view of a still further
embodiment of modular
panel units using panels with a further dual modular panel flange design; and
- 10 -
CA 2885428 2019-05-02
[0059] Figure 29 is a partial side elevation view of a still further
modular panel unit
embodiment using panels with another dual flange design.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0060] Turning now to Figure 2, a single modular upstanding seam flange
panel 10 is
shown in cross-section, with a seam flange 12 at its distal end 14. The seam
flange preferably
extends along or adjacent the entire length or lateral edge of the panel which
may be, for
example, up to 45 feet in length and from 2 to 4 feet in width. A second
flange will be located
along the opposite edge of the modular panel parallel to flange 12. Of course,
the panels may
be provided in other sizes if desired.
[0061] Modular panel 10 may be extruded from polycarbonate (or other resin)
and may
have a plurality of internal cells in a honeycomb configuration 17 (or other
configuration)
disposed in the interior of the panel between its outer surface or wall 16 and
its inner surface
18. Modular panels 10 with this upstanding seam flange design are known in the
art and
described for example in U.S. Pat. No. 6,164,024. Modular panels with
upstanding seam
flanges of the design shown in Figure 2 and modified versions thereof that
function generally
in the same fashion, made of polycarbonate or other resins, will be referred
to herein as
"modular panels," "modular upstanding seam flange panels," etc.
[0062] The preferred honeycomb cell configuration 17 of modular glazing panels
10 helps
control the panel thermal expansion in all directions and gives it resistance
to impact and wind
and snow loading while maintaining superior light-diffusion capabilities.
Particularly
desirable modular panels 10 are available from CPI Daylighting, Inc., 28662
Ballard Drive,
Lake Forest, IL 60045 as PENTAGLAS NANO-CELL architectural panels.
[0063] Upstanding seam flanges 12 have a series of sawteeth 20 along their
inner surface
22 and generally will be flat along their outer surface 24 optionally with a
protruding open
resilient bubble corner area 146 to improve sealing between adjacent panels as
will be
discussed below. The surface 26 of the flanges (at the top or bottom of the
flanges depending
on how the flange is oriented in the panel unit) may also be flat.
Additionally, preferably the
flanges also include internal cells to give them enhanced strength,
resilience, and
expansion/contraction properties as described above. Other modular panel
designs will be
addressed below. In all cases the modular panels have a thin low ultimate
tensile strength skin
which runs along the entire surface of the panel.
- 11 -
CA 2885428 2019-05-02
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
[0064] In accordance with one embodiment of the invention for use with
modular panels,
Figure 3A shows a second locking engagement member 30 and its corresponding
first
locking engagement member 32 and a metal retention clip 34 juxtaposed between
the two
locking engagement members. Members 30 and 32 are designed to interlock as
illustrated in
Figure 3B. Both locking engagement members may be made, for example, as
aluminum
extrusions and are each configured for attachment to upstanding seam flanges
12 of
corresponding pairs of modular panels to construct a glazing panel unit while
armoring or
cladding the seam flanges with high tensile strength metal to thereby
strengthen and stiffen
the panel edges and prevent damage at the points of attachment of retention
clips 34. When
metal retention clips are used, a particularly desirable metal-to-metal
engagement is achieved.
However, the locking engagement members alternatively may be made of
engineering
plastics, pultruded fiberglas, metal plast, or other appropriate high ultimate
tensile strength
materials to armor or clad the seam flanges (or panel edges in the embodiments
of Figures
25-26) with this high tensile strength material.
[0065] The armoring or cladding of the skin of the modular panel flanges by
the locking
engagement members protects the flanges (and the panels) from damage at the
points of
contact by the retention clips and elsewhere that might otherwise occur due to
loading and
stresses from wind or snow loads and panel expansion and contraction. It also
increases the
strength of the entire glazing panel unit, making it possible to reduce the
weight of the skin of
the two panel flanges and to use the glazing panel unit across spans and in
other applications
in which conventional panel units could not be used without additional
retention clips and
structural support. Indeed, unlike conventional systems where the bearing load
is sustained
primarily by the bottom or inner panel, in present embodiments the load is
sustained
primarily by the first and second engagement members and the top or outer
panel so an
overall lighter skinned bottom or inner modular panel can be used.
[0066] In Figure 3A, second locking engagement member 30 is disposed
vertically (as it
would be, e.g., at rest in a horizontal roof or skylight installation) and
first locking
engagement member 32 is angled with respect to the second locking engagement
member to
correspond to the orientation of the locking engagement members during the
course of an on-
site or erection process which concludes with the panel units installed in the
juxtaposed
arrangement of, e.g., Figure 4B. Alternatively, the glazing panel units may be
installed by
directly aligning them rather than angling one of the panels and sliding the
two panel units
laterally together until the locking engagement members are fully engaged or
interlocked.
[0067] Second locking engagement member 30 includes a base 36 which is
oriented
vertically in the figure and generally U-shaped upwardly and downwardly
directed arms 38
- 12 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
and 40 which depend from the back surface 42 of the base. Arm 38 includes a
generally flat
horizontal portion 44 and a generally flat vertical portion 46. Horizontal
portion 44 includes
an optional angled outer corner portion 45 to enhance the resilience and
resistance to
breakage of arm 38 at this corner. The back surface of the base and the U-
shaped arm
together define an upwardly directed cavity 48 for receiving and locking onto
the flange of
the top modular panel of glazing panel unit 142 illustrated in Figures 4A and
4B. Finally, at
least one sawtooth and preferably at least two sawteeth 50 (as shown) project
from back
surface 42 into cavity 48 to engage sawteeth 20 on upstanding flange 12 of
panel 10 in the
assembly of the modular panels onto locking engagement member 30. Sawteeth 50
include
horizontal portions 52 and angled portions 54 which are angled and dimensioned
to engage
sawteeth 20 of the modular panel flange.
[0068] In a like manner, downwardly directed U-shaped arm 40 includes a
generally
horizontal portion 56 and a vertical portion 58. The horizontal and vertical
portions define a
downwardly directed cavity 60 which will engage the upstanding flange of a
second panel of
the modular panel unit assembled on locking engagement member 38. Horizontal
portion 56
may be stepped downwardly, as shown, to produce a slot 62 having an upwardly
directed lip
64 for receiving engagement hook 74 of retention clip 34 and achieving a metal-
to-metal
retention of the panels and panel unit. Other alternative structural
arrangements for
engagement between the retention clip and the locking engagement member may be
used and
the engagement members may alternatively be made of engineered plastics,
pultruded
fiberglas, metal plast, or other appropriate high ultimate tensile strength
materials.
[0069] Retention clip 34 includes a base 66 with a hole 68 for receiving a
fastener 70
which will be driven or screwed into a [mein, rafter or other support (not
shown) to hold
adjoining juxtaposed glazing panel units (e.g., units 142 and 144 of Figure
4B) in place. Base
66 supports an upstanding wall 72 and an engagement hook 74. The hook includes
a ledge
75 and a downwardly directed lip 76 dimensioned to fit within slot 62 (or 126)
and engage
the inner surface of locking engagement member lip 64 to retain second locking
engagement
member 30 and the adjoining interlocked first locking engagement member and
their modular
panels/glazing panel units in place during the on-site erection of the desired
sloped glazing,
skylights, roofs, walls, and other architectural structures from series of
juxtaposed panel
units. However, in short span applications the panel units may be
interconnected and erected
in place without the use of retention clips.
[0070] Horizontal portions 44 and 56 of upwardly and downwardly directed
arms 38 and
40 are spaced from each other to define or wall in a horizontally directed
inner cavity 80.
Inner cavity 80 receives a guide member 82 of first locking engagement member
32 and in
- 13 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
doing so helps form an inner gutter 81 (Figure 3B) in the final interconnected
locking
engagement member pair 83, which will be discussed in more detail below. The
guide
member helps resist loads on the interconnected locking engagement members and
so must
be strong and long enough to accommodate the maximum expected load on the
interconnected engagement members.
[0071] Preferably a resilient sealing strip 84 will be positioned in cavity
80 along the
back surface 42 of base 36 in horizontally directed inner cavity 80 to engage
guide member
82. This establishes a gutter seal 90 as illustrated in Figure 3B to help
achieve and maintain a
water-and air-tight condition in inner gutter 81 while also enhancing the
soundproofing
properties of the final interconnected locking member pair 83. Inner gutter 81
in turn carries
the water to an open end of the interconnected locking engagement members
where a sill and
appropriate flashing will be provided to collect escaping water and to carry
it away from the
slopped glazing, skylight, roof, wall or other architectural structure.
[0072] Also, top corner 85 of step portion 62 may have a nub 86 with front
and back
inclined surfaces 87 and 88 which facilitate the interlocking process as will
be described
below. Finally, an optional water rail 91 projects down and away from the
outer surface 92
of vertical portion 46. As will be discussed further below, this rail directs
any water that
infiltrates or is drawn down between the adjacent top panels ofjuxtaposed
panel units and
moves down surface 92 due to surface tension effects or through the gap 96
between vertical
portions 46 and 108 away from gutter seal 90 to minimize the likelihood that
such infiltrating
water will find its way to the gutter seal.
[0073] Turning now to first locking engagement member 32 in Figure 3A, it
is seen that
this locking engagement member has a base 100 and U-shaped upwardly and
downwardly
directed arms 102 and 104 which depend from the back surface 106 of the base.
Arm 102
includes a generally flat vertical portion 108, and a bottom 110 made up of a
first flat portion
112 generally perpendicular to base 100 and a second upwardly angled flat
portion 114. This
bottom configuration is chosen to enhance the resilience and resistance to
breakage like the
corner on arm 38 described above and is, of course, optional. Back surface 106
of base 100
and U-shaped arm 102 together define a generally upwardly directed cavity 116
for receiving
the downwardly directed flange of a top modular glazing panel of a glazing
panel unit.
Finally, sawteeth 50 project from back surface 106 into cavity 116 to engage
sawteeth 20 on
upstanding flange 12 of a modular panel 10. Sawteeth 50 include horizontal and
angled
portions that are dimensioned to engage sawteeth 20 of the modular panel
flange
- 14 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
[0074] Downwardly directed U-shaped arm 104 of the first locking member
includes a
generally horizontal portion 120 and a vertical portion 122. Arm 104 and base
back surface
106 define a downwardly directed cavity 124 which will engage the upstanding
flange of the
second modular glazing panel unit 142 (Figure 4A).
[0075] As in the case of first locking engagement member 30, horizontal
portion 120 may
be stepped downwardly, as shown, to produce a slot 126 having an upwardly
directed lip 128
for receiving engagement hook 74 of retention clip 34 to achieve a metal-to-
metal
engagement. Other alternative structural arrangements for metal-to-metal
engagement
between the retention clip and the locking engagement member may, of course,
be used.
Also, as can be readily understood from Figure 3A, retention clip 34 may be
rotated 180
degrees to engage slot 126 and lip 128 of the first locking engagement member
rather than
step 62 and upwardly directed lip 64 of the second locking engagement member,
depending
on construction requirements and the desire of the installer erecting the
modular glazing
panel units in place. Of course, as noted earlier, in less preferred
embodiments other locking
configurations could be used and, indeed, only one of the first and second
locking
engagement members may be provided with the slot and lip for accommodating the
retention
clip. In all cases, the resulting metal-to-metal interconnection or
interlocking represents a
significant advance over prior systems, providing greatly enhanced resistance
to wind load
and other advantages as discussed earlier.
[0076] Guide member 82 of first locking engagement member 32 includes a
spine 83 that
projects generally perpendicularly relative to surface 106 of base 90 and in
this embodiment
extends from portion 120 of downwardly directed U-shaped arm 104. Member 82
has a nub
130 adjacent its distal end 132 which projects downwardly from its bottom
surface 134 to
cooperate with nub 85 on portion 56 of the second locking engagement member
when the
first and second locking engagement members are interlocked as will be
explained below.
Nub 130 has front and back inclined surfaces 136 and 138 which facilitate the
interlocking
process and help keep the corresponding locking engagement members together as
installation of the glazing panel units proceeds.
[0077] An end flange 140 is located at the distal end of spine 83 of guide
member 82.
Flange 140 has a generally flat outer surface 142 and an optional hook portion
145 which is
dimensioned to rest below horizontal portion 44 of the second locking member
when the first
and second locking engagement members are interconnected as in Figure 3B to
help limit
water entering the inner gutter from reaching gutter seal 90 and to limit
upward movement
due to loading on the guide member. Finally, spine 82 and end flange 140 are
dimensioned
to ensure that when the first and second locking engagement members are
interlocked as in
- 15 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
Figure 3B, flat outer surface 141 will abut (and preferably compress)
resilient insulating strip
84 in cavity 80 of the second locking member to produce a reliable air, water
and sound seal.
[0078] Turning now to Figures 4A and 4B, locking engagement members 30 and
32 are
shown with modular glazing panels 10 locked into respective upwardly and
downwardly
directed cavities 48, 60, 116, and 124 of the locking engagement members by
the engagement
between sawteeth 20 of the panel units and sawteeth 50 of the locking
engagement members.
This forms glazing panel units 142 and 144. Such units may be assembled either
on-site in a
convenient ground level area or off-site and transported to the work site.
Once at the
worksite the panel units will be erected into sloped glazing, skylights,
roofs, walls or other
architectural structures.
[0079] The modular panels in glazing panel units 142 and 144 may include
optional
resilient areas in the form of, e.g., preferably protruding open bubble areas
146 at the lateral
edges of the panels. These open bubble areas substantially increase the
resilience of the panel
edges so that they can deform when the corresponding lateral edges of the
panels move in and
out due to panel expansion and contraction. The adjacent resilient panel areas
cooperate with
the first and second engagement members which also accommodate lateral
movement. Thus,
unlike prior art systems where the lateral panel expansion may cause the
modular panels to
bow, the panels of glazing panel units 142 and 144 remain flat. At the same
time, these
resilient edges close the gap between adjacent panels in the panel units to
help in limiting or
preventing air, water and sound infiltration. Other gap sealing approaches can
of course be
used.
[0080] Referring to Figures 4A and 4B, the installation method of the
invention may
proceed as follows:
A. First, exemplary 40 foot glazing panel units 142 and 144 of Figure 4A
are
assembled, transported to the work site if necessary, and then preferably
oriented and pre-positioned conveniently to the location where they will be
installed. It should be noted that panel unit 142 has a first locking
engagement member at its opposite (hidden) lateral edge whereas panel unit
144 has a second locking engagement member at its opposite (hidden) lateral
edge.
B. Next, unit 142 may be positioned on the appropriate purlin or rafter
(not
shown) and locked in place by a series of retention clips 34 spaced, e.g.,
about
4 to 10 feet apart with their engagement hooks engaging slots 62 and lips 64
- 16 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
of the second locking engagement member which in turn engages and armors
or clads the 40 foot modular panel flanges. As noted earlier, attachment to
the
first locking engagement members may proceed from the other side by
rotating the retention clip 180 degrees and first installing panel unit 144 by
way of attachment slots 126 and lips 128 of the first locking engagement
members. Also, for shorter spans the assembly may not require intermediate
support making it possible to dispense with the use of retention clips.
C. Assuming that unit 142 is already affixed in position, modular glazing
panel
unit assembly 144 is then juxtaposed against unit 142 with its lateral edge
160
opposite the lateral edge 162 of the already affixed panel unit 142. In this
orientation, guide member 82 will be located opposite inner cavity 80 of
second locking engagement member 30.
D. Then, panel unit 144 will be pivoted about adjoining lateral edges 160
and
162 as inclined surface 136 of nub 130 on the guide member first engages
inclined surface 87 on nub 85 of the second member and the nub 130 rides
over numb 85 providing the installer with a tactile indication that the first
and
second locking engagement members are properly interconnected with flat
outer surface 141 of flange 140 abutting and preferably compressing resilient
insulating strip 84 as depicted in Figure 3B and the lower lateral panel edges
164 and 166 abutting as well. When the locking engagement members are
interconnected in this way abutting inclined surfaces 88 and 138 will maintain
glazing units 142 and 144 together so that the installer can move to the next
lateral adjacent position to begin installing the next panel unit.
E. In an alternative installation approach, panel unit 144 may be
vertically
aligned and slid horizontally into place until the locking engagement members
are interconnected.
F. This process continues until the outer panel units are reached. The
outer
panels are affixed by conventional perimeter framing. Thus a series of units
held in place by retention clips as illustrated in Figure 4B and confined by
outer panels or separate conventional structural members to ensure that the
entire installation will withstand substantial loads even up to hurricane
levels
while providing outstanding resistance to air, water and sound infiltration as
well as outstanding energy conservation characteristics and the ability to
- 17 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
accommodate lateral expansion and contraction of the modular panels and
glazing panel units to a degree not heretofore thought possible.
[0081] Figures 5A and 5B illustrate an alternative embodiment of the
invention in which
first and second engagement locking engagement members 200 and 202 are used to
assemble
panel units 204 and 206. As is apparent in these figures, locking engagement
members 200
and 202 are taller than locking engagement members 30 and 32 thus establishing
a taller and
larger airspace between the modular panel pairs of the glazing panel units.
For example, the
airspace of the units of Figures 4A and 4B may be, for example, about 2.5
inches in height
whereas the airspace of the units of Figures 5A and 5B may be, for example,
about 4.0 inches
in height. This height difference is achieved by incorporating a second inner
cavity 80A and
corresponding second guide member 82A spaced a distance "x" from the first
inner cavity.
Smaller and larger inner cavities and guide members as well as more than two
pairs of these
features may be used. These additional features further enhance the
installation process by,
e.g., improving the signaling and interlocking operation of the first and
second locking
engagement members. The greater height airspace panel units are also stiffer,
further
enhancing their ability to withstand loads and the added lower inner gutter
(which may
optionally be fitted with a gasket strip 81A) further limits water, air and
sound infiltration.
[0082] Figure 6 illustrates yet another alternative embodiment of the
invention in which
first and second locking engagement members 250 and 252 are used. These
locking
engagement members generally correspond to locking engagement members 200 and
202 of
Figures 5A and 5B except that the locking engagement members are provided with
pairs of
outer brackets 254 and 256 for holding side stiffener bars 258. The side
stiffener bars run
along the locking engagement member improving the section moment of inertia of
the
locking engagement members, thereby enhancing the load capacity
characteristics of the
overall panel unit and its ability to handle longer spans. The side stiffener
bars are preferably
made of solid aluminum or steel although they may be hollow if desired.
[0083] Figure 7 depicts a modular panel 300 having a double flange design
comprising an
outer flange 302 and an inner standing seam flange 304. Such panels are shown
installed in
first and second locking engagement members 306 and 308 in Figures 8A and 8B
forming
panel units 310 and 312. The locking engagement members arc interlocked using
the
pivoting or sliding interlocking motion of the earlier-described locking
engagement members
and form an inner gutter 324 in the same way using like structural features.
Upstanding lip
314 onto which a hook 74 of a retention clip 34 is fit again achieves the
metal-to-metal
engagement discussed earlier. Additionally, the second locking engagement
member
includes a ledge 316 (on which outer panel flange 302 rests to provide
enhanced load bearing
- 18 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
capability) and a downwardly directed shoulder 318. First locking engagement
member 306
has a corresponding first shelf 320 for supporting the outer flange 302 of the
adjacent panel
300 of panel unit 310. Shelf 320 jogs downwardly to provide a second lower
shelf 322 which
engages downwardly directed shoulder 318 of the second locking engagement
member when
the panel units are interconnected as depicted in Figure 8B. The engagement of
shoulder 318
and shelf 322 therefore forms the first line of defense against the
infiltration of water into the
inner gutter 324 in the interconnected units and also provides enhanced load
bearing
capabilities (Figure 8B).
[0084] Figure 9 is a partial view of the top modular panels of two panel
units
interconnected using first and second locking engagement members 301 and 303.
This
Figure is included to illustrate an alternative embodiment in which the
lateral edges 305 and
307 of the panels are spaced from each other. In this arrangement, a resilient
gasket 309 is
fitted into the gap between the panel edges and held in place by a pin 311
affixed to locking
engagement member 300.
[0085] Figure 10 illustrates another embodiment in which pairs of modular
glazing panels
10A and 10B are locked into respective upwardly and downwardly directed
cavities 406/408
and 410/412 (Figures 11A and 11B) of metal first and second locking engagement
members
402 and 404. Modular panel units 414 and 416 are formed in this way and then
assembled
together by interlocking the first and second members as illustrated in Figure
10.
[0086] Turning now to Figure 11A, first locking engagement member 402 of
Figure 10
has a back wall 418 interrupted at its midpoint by a slot 420 which extends
along the first
locking engagement member and is positioned to open into the area between the
paired
modular panels of a glazing panel unit as can be seen in Figure 10.
Fireproofing, aluminum
members, sound proofing or insulation provided with tabs as appropriate may be
fixed in the
area between the panel pairs by attaching the tabs to this slot as desired.
Back wall 418
extends between the top edge 422 and the bottom edge 424 of the first locking
engagement
member.
[0087] A cantilever arm 426 extends from the inner surface 421 of back wall
418.
Cantilever arm 426 include a base portion 430 that is generally perpendicular
to the inner
surface of the back wall and has a predetermined width "W." An angled member
432
extends from base 430 and the cavity bottom member 434 extends laterally from
upwardly
angled member 432. Finally, a cavity sidewall member 436 extends generally
parallel to
back wall inner surface 421 to form one side of cavities 406/408. The opposite
side of the
- 19 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
cavities comprises a portion of inner surface 421 and a pair of sawteeth 439
at the top and
bottom of the locking engagement member which project into cavities 406 and
408.
[0088] As can be seen in Figure 10, sawteeth 20 of seam flanges 12 of
glazing panel 10A
or 10B will fit within cavity 406 or 408 with the panel sawteeth engaging
sawteeth 439.
When the seam flanges are pressed home into the cavities, cantilever arms 426
will flex away
from back wall inner surface 421 to permit the flanges to enter the cavities
after which the
cantilever arms will resile back to their original position locking the
flanges into place.
Additionally, in order to facilitate the assembly of the panel sawteeth into
the cavity, a bevel
440 may be formed on the inner surface of sidewall member 436 (Figure 11A) to
help guide
the panel sawteeth into place in the cavity.
[0089] A "T" shaped member 442 projects from the outer surface 444 of
sidewall
member 436. The T-shaped member presents an outer abutment surface 446 to help
ensure
proper parallel alignment of the modular panel units when then they are
interconnected by
way of first and second locking engagement members.
[0090] First locking engagement member 402 also includes slots 449 running
behind
abutment surface 446 of T-shaped member 442. These slots may receive a locking
portion
445 of an elongated gasket 443 (Figure 10). When these gaskets are positioned
as illustrated
in Figure 10, they achieve an enhanced sealing at the interface between
adjacent panel ends
of each modular panel unit.
[0091] The respective inner surfaces 421, 431 and 433 of back wall 418,
cantilever arm
base 430 and cantilever sidewall member 436 define a cavity 452 for receiving
the upper
retention portion 464 of a unique clip member 454 which is described
immediately below and
illustrated in Figures 12A-12C and 14. Inner surface 433 of the cantilever
sidewall member
also includes a boss 447 that helps insure that the upper retention portion of
clip member 454
is Firmly retained in cavity 452 and maintained in abutment against inner
surface 428.
[0092] First locking engagement member 402 also includes a guide member 470
that is
disposed generally perpendicularly with respect to back wall 418 and projects
from the inner
surface 474 of slot wall 472. The guide member includes a spine 476 and a
generally
rectangular flange 478 at its distal end. Flange 478 includes an abutment
surface 482 that is
generally parallel to back wall 418 and is of a height "H" corresponding to
the height of a
receiving cavity 490 of second locking engagement member 404 (Figure 11B) to
insure that
the flange fits properly in the receiving cavity of second locking engagement
member 404, as
will be discussed below. Finally, it is noted that flange 478 includes outer
corners 484.
- 20 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
[0093] Figure 11B illustrates second locking member 404. As described above
with
respect to the first locking engagement member, this locking engagement member
includes a
back wall 418' interrupted at its midpoint by a slot 420' which extends along
the first member
and is positioned to open into the area between the paired panels of a modular
panel unit.
Fireproofing or insulation may be fixed in the area between the panel pairs by
way of a tab
attached to this slot, as desired, as discussed earlier with respect to
locking member
engagement 402. Back wall 418' extends between the top 422' and the bottom
424' of the
first locking engagement member.
[0094] Cantilever arms 426' extend from the inner surface 421' of back wall
418'.
Cantilever arms 426' include a base portion 430 that is generally
perpendicular to the inner
surface of the back wall and has a predetermined width "W'." An angled member
432'
extends from base 430' and the cavity bottom member 434' extends laterally
from upwardly
angled member 432'. Finally, a cavity sidewall member 436' extends generally
parallel to
back wall inner surface 421' to form one side of cavities 410 and 412. The
opposite side of
the cavities comprises a portion of inner surface 421 and a pair of sawteeth
438 at the top and
bottom of the locking engagement member which project into cavities 410 and
412.
[0095] As can be seen in Figure 10, sawteeth 20 of glazing panel 10A or 10B
will fit
within cavity 410 or 412 with the panel sawteeth engaging sawteeth 439.
Additionally, in
order to facilitate the assembly of the panel sawteeth into the cavity, a
bevel 440' may be
formed on the inner surface of sidewall member 436' to help guide the panel
sawteeth into
place in the cavity.
[0096] A "T" shaped member 442' projects from the outer surface 444' of
sidewall
member 436'. The T-shaped member presents an outer abutment surface 446' to
help ensure
proper parallel alignment of the panel units when they are interconnected by
way of the first
and second members.
[0097] Second locking engagement member 404 also includes slots 449'
running behind
abutment surface 446' of T-shaped member 442'. These slots may receive a
locking portion
445 of an elongated gasket 443 (Figure 10). When these gaskets are positioned
as illustrated
in Figure 10, they achieve an enhanced sealing at the interface between
adjacent panel ends
of each modular panel unit.
[0098] The respective inner surfaces 421', 431' and 433' of back wall 418',
cantilever arm
base 430' and cantilever sidewall member 436' define a cavity 452' for
receiving the upper
retention portion 464 of a unique clip member 454 which is described
immediately below and
- 21 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
illustrated in 12A-12C and 14. Inner surface 433' of the cantilever sidewall
member also
includes a boss 447' that helps insure that the upper retention portion of
clip member 454 is
firmly retained in cavity 542 and maintained in abutment against inner surface
428'.
[0099[ Second locking engagement member 404 has a flange-receiving cavity
490
positioned along the midline of the locking engagement member which opens away
from
back wall 418'. Flange receiving cavity 490 is defined by side members 492
which are
oriented generally perpendicularly with respect to back wall 418'. Outwardly
angled lips 494
are formed at the distal edges of the side members. These lips will engage
outer corners 484
of flange 478 of the first locking engagement member to help guide the flange
into the
flange-receiving cavity when panel units are moved into interlocking position.
[00100] In some embodiments, a resilient sealing strip 496 will be applied to
the bottom
surface 498 of the flange-receiving cavity. Alternatively, such a resilient
strip may be applied
to abutment surface 482 of flange 478 of first engagement member 402, or
resilient strips
may be applied to both the abutment surface of the flange and the inner
surface of the cavity
bottom. When one or more such resilient strips are used and the locking
engagement
members are interconnected with the abutment surface 482 of the flange
adjacent the bottom
surface 498 of the flange-receiving cavity, the resilient insulating strip(s)
will be compressed
to achieve improved soundproofing and air/water sealing.
[00101] Clip member 454 is depicted in Figures 12A-12C. As can be seen in
these
figures, the clip member includes a base 456 having an opening 458 for
receiving a fastener.
A sidewall 460 extends generally perpendicularly from base 456. Sidewall 460
is slit along
462 so that the upper retention portion 464 of the sidewall can be bent
substantially
perpendicularly to project in the opposite direction from base 456. Upper
retention portion
464, which may be radiused at corners 465 to facilitate insertion into cavity
452, is
dimensioned to fit snuggly in cavity 452 for locking edge glazing panel units
in place from
their opposite ends, as will be described below. This is made possible by the
enhanced
strength/moment of inertia achieved by the armoring or cladding of the flanges
of the glazing
panels by the clip receiving locking engagement members.
[00102] Figure 13 illustrates a vertical opening 500 into which glazing panel
units may be
installed. In one installation approach, sill frames 502, as illustrated in
Figure 14, 538A-
538B may be used. Sill frames 502 may be generally "L" shaped, as shown, and
include a
base portion 504 and an upstanding portion 506 that includes gasket holding
means 508 at its
distal end (Figure 15). The gasket holding means include a cavity 510 Figure
510 for
receiving the base 514 of a resilient gasket 512. As can be seen in Figure 15,
gasket 512
- 22 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
presents a generally flat surface 516 generally parallel to the upstanding
portion 506. Base
portion 504 of the seal frame includes a series of spacer legs 518A, 518B and
518C which are
designed to rest against a structural support member to which the sill frame
is attached.
[00103] Attachment of the sill frame to support frame in 520 (Figure 13) may
be achieved
by passing a screw fastener 522 through pairs of bores 524A and 524B, spaced
respectively
along base 504 of the support frame and foot 526 of spacer leg 518B and driven
into support
framing 519. When the series of screws along the sill frame member are driven
home, feet
526, 528 and 530 of spacer legs 518A, 518B and 518C will rest firmly against
the top surface
532 of the support framing.
[00104] Returning to Figure 13 and opening 500, is noted that this opening is
framed out
with a header 540 at its top, a sill 542 at its bottom and side framing
members 544 and 546.
[00105] Installation of a series of glazing panel units 538A-538E may be
accomplished as
follows.
1. First, sill frames 502 are affixed to the header and sill using a series
of screw
fasteners 522, as described above.
2. Then, glazing panel unit 538A is slid into place against side member 546
with
the back surface of the panel unit abutting gaskets 512 on upstanding portion
506. This first
panel unit is locked in place by positioning upper retention clip portion 464
in the clip
receiving cavity 452 of one of first and second locking engagement members of
the panel
unit. Once panel unit 538A is properly positioned with the clips in place, a
fastener may be
passed through hole 458 in the base 456 of the clip to fasten panel 538A in
place.
3. An L-shaped cover element 554 may then be employed as shown in Figure 15
to cover the sill frame and the intetface between the modular panel unit, the
sill frame and the
support member for aesthetic purposes. L-shaped cover 554 includes a base 556
which is
press fit into a receiving cavity 558 in the sill frame. A gasket receiving
member 560
preferably is provided at the distal end of base 554 of the L-shaped cover and
a gasket 555
disposed therein to provide a seal against the surface of the front panel of
the modular panel
unit.
4. Once glazing panel unit 538A is fixed in place, successive panel units
538B,
538C, 538E and 538F are installed by aligning and moving the flange of one of
the first and
second locking engagement members of each panel unit into the corresponding
flange
- 23 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
receiving cavity of the other one of the first and second locking engagement
members so that
the panels are in position with the abutment surfaces of T-shaped members 442
against each
other. In the course of assembling the glazing panel units into place in this
fashion, clip
members 454 will be provided at opposite ends of each modular panel unit and
then screwed
into a support member to lock the panel units in place.
[00106] If it is subsequently necessary to remove any particular panel unit,
it will only be
necessary to disconnect its clip members and remove it from opening 500.
[00107] Since the first and second locking engagement members greatly enhance
the
structural characteristics of the panels and hence the modular panel units,
substantially
enhanced spans may be covered in this fashion in vertical, horizontal and
angled applications.
However, when the span exceeds the structural specifications of these metal
cladded units,
intermediate structural supports may be provided with clips affixed to the
first and second
locking engagement members and the intermediate structural elements.
[00108] The following figures illustrate additional embodiments.
[00109] Figure 16 illustrates an embodiment in which modular panel units 602
and 604
having lower panels 606 and 608 with their flanges 610 and 612 spaced a
distance "Y" from
the edges of the panels and their upper panels 618 and 620 spaced a larger
distance "X" from
the edge of the panels to achieve a radiused configuration or circularly
disposed assembly of
glazing panel units. The locking engagement members in this embodiment
correspond
generally to locking engagement members 402 and 404 of Figures 11A and 11B
except that
guide member 626 of locking engagement member 622 has a circular leading edge
628 which
accommodates the radius configuration since it is able to rest within cavity
629 of locking
engagement member 624.
[00110] Figure 17 is another embodiment in which a radiused configuration is
achieved.
In this embodiment, the upstanding flanges 630 and 632 of lower panels are
located at the
lateral edges 638 and 640 of these panels and the flanges 642 and 644 of the
upper panels are
spaced from the lateral edges 646 and 648 of the upper panels. Also, in this
embodiment, the
first locking engagement member 650 includes a flange 652 with a round distal
end 654
which facilitates the angled (nonperpendicular) disposition of the first and
second
interlocking engagement members. A gasket 656 may optionally be fitted to the
outer edge
of the curved flange of the guide member to seal against the bottom surface
658 of the flange
receiving cavity 660 of the second locking engagement member 662 as shown.
Additionally,
- 24 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
in this embodiment, the spine 664 of the guide member is designed to be of a
length that
ensures that the outer surface of the guide member sits properly in the flange
receiving cavity.
[00111] In Figure 18 the sawteeth flanges 680 and 682 of the top and bottom
panels 684
and 686 of the modular panel units are again spaced from the lateral edges 688
and 690 of the
panels. However, a radiused configuration is achieved in this embodiment by
inserting a
spacer member 692 between the top panels of the adjacent panel units. Gaskets
694 of the
first and second locking engagement members abut a center strip 696 of the
spacer member
to achieve a sound and water/air seal.
[00112] Figure 19 illustrates hermaphroditic locking engagement members 700
which may
be used to interchangeably because each includes like guide members 702 and
flange
receiving cavities 704/706. As can be seen in this figure, receiving cavity
706 includes a
gasket 708 which engages the distal end of one of the guide members to produce
a seal when
the locking engagement members are interlocked. This figure also includes
gaskets 708
which are fit into the hermaphroditic locking engagement members like, for
example, gaskets
443 in Figure 10 to produce a seal as described above.
[00113] Figures 20A-20B illustrate embodiments in which first and second
locking
engagement members 730/732 and 760/762 include rigid elongated members or
extensions
734/736 and 764/766 which are designed to extend below the lower panels 738
and 768 of
the modular panel units (or when single panels are used, below the single
panels) to improve
the rigidity/moment of inertia of the panel units (or panels), so that they
can extend over
greater spans without intermediate supports.
[00114] Figure 21 illustrates an embodiment in which single panels 780 are
interconnected
by first and second locking engagement members 782 and 784 in accordance with
an
embodiment of the invention in which interlocking strengthening extensions
786/788 and
790/792 are provided. In this embodiment, strengthening extension 790 is fixed
onto a purlin
or other support member by passing a fastener through a bore in the
strengthening extension,
as shown in this figure. Most importantly, downward movement of the panels due
to, e.g.,
positive pressure of a snow load is resisted by strengthening extension 786
which supports
and prevents downward movement of strengthening extension 788. On the other
hand,
upward movement of the panels due to, e.g., wind load is resisted by
strengthening extension
790 which abuts strengthening extension 792 and prevents it from moving
upwardly.
- 25 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
[00115] Turning now to Figures 22A and 22B, first and second locking
engagement
members 800 and 802 are shown with top and bottom modular panels 804A/804B and
806A/806B in place in the locking engagement members.
[00116] Locking engagement members 800 and 802 are constructed generally like
first
and second locking engagement members 402 and 404 of Figures 11A-11B. However,
as
will be described below, locking engagement members 800 and 802 differ in the
structure of
their respective male and female members 808 and 810 which are employed in
engagement
members 800 and 802 in lieu of guide member 470 and receiving cavity 490 of
engagement
members 402 and 404.
[00117] Male member 808 includes a spine 812 that projects generally
perpendicularly
from the front surface 816 of back wall 814. Spine 812 (as well as spine 476
of locking
engagement member 402 and the spine of locking engagement member 32)
optionally may
be offset from 90 at an angle sufficient to accommodate the angle between
adjacent panel
units of curved panel unit installations.
[00118] Spine 812 extends from back wall 816 to a pair of guide, pull-out, and
pivot
support "T"-shaped rails 818A and 818B which are disposed generally
perpendicularly to the
rail with the outer faces 820A and 820B of the top of the "T" generally
parallel to the
corresponding surfaces of spine 812 to help guide the first member into the
interlock cavity
and to abut the inner surfaces of the cavity sidewalls. The leading edges 822A
and 822B
optionally are radiused as shown to facilitate entry into second member 810.
[00119] Continuing along spine 812, at a distance "A" from guide, pull-out,
and pivot
support T rails 818A and 818B, a pair of generally flat catch rails 822A and
822B are located
and oriented perpendicularly to spine 812. The distal edges of the catch rails
have bevels
824A and 824B. Finally, spine 812 projects beyond the catch rails along a
distal lip 826.
The distal end of the lip may be beveled to present a knife-like leading edge.
[00120] Female member 810 includes sidewalls 826A and 826B which define an
interlock
cavity 828 for receiving male member 808. A series of serrations 830A and 830B
are formed
along the inside surface of sidewalls 826A and 826B. While three serrations
are shown, any
desired number may be used. Sidewalls 826A and 826B extend to their distal
edge
832A/832B where angled walls 834A and 834B are present to facilitate the
entrance of
member 808 to cavity 828. Distal edges 832A and 832B are spaced from the first
of
serrations 830A/830B a distance "B". Finally, a gasket 836 is located at the
closed distal end
of cavity 828.
- 26 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
[00121] A pair of panels 804A/806A are mounted in first locking engagement
member 800
and a pair of panels 804B/806B are mounted in second locking engagement member
802 to
respectively form panel units 840 and 842.
[00122] In Figure 22A, panel units 840 and 842 are shown with their locking
engagement
members interlocked and a retaining clip 844 holding the panel units against a
purlin or other
support member (not shown). As in this and the various other locking
engagement member
designs described earlier, panel expansion and contraction due to ambient
temperature
changes is accommodated by generally lateral movement of the first member of a
first
locking engagement member in the receiving cavity of the second locking
engagement
member.
[00123] In the configuration of this figure, an internal gutter 846 is formed
to receive any
water that infiltrates across the space between panels 804A and 804B and moves
past gaskets
848A and 848B. Additionally, pressure breaker chambers 850 and 852 are formed
between T
rails 818A and 818B and catch rails 822A and 822B and the seal formed along
lip 826 where
it engages gasket 836. Also, it is noted that a particularly efficient sealing
is achieved
because of the pressure concentrated along the distal edge of the lip which
may partially
penetrate the gasket. As illustrated in Figure 23 if the lip penetrates far
enough into the
gasket, a seal will be achieved as well along the interstice between the face
of the catch rail
and the exposed surface of the gasket. In a less preferred alternative a lip
will not be
provided but greater force will be required in order to establish a seal.
[00124] Figure 22A shows what happens in this structure when a negative (wind)
force is
applied along the surface of panels 804A and 804B tending to pivot the first
locking
engagement member away from the second locking engagement member. Some of the
wind
force may be absorbed by flexure of the panels which are made of flexible
resin. In this case,
edge 832A acts as a leverage point where it engages the outer face of T rail
818A so that the
portion of spine 812 extending between the T rail and wall 816 acts as a lever
arm producing
a high downward force along bevel 824B of the catch rail which engages one of
serrations
830B to concentrate the force along the outer bevel edges and resist further
movement of the
first locking engagement member from its engagement with the second locking
engagement
member. Distances "A" and "B" are made generally equal to ensure that the T
rail engages
edge 832A while the bevel of the catch rail is located adjacent the
serrations.
[00125] When a positive load is applied due to, for example, snow accumulating
on panels
804A and 804B, the orientation of the first engagement member is reversed so
that the bevel
rests in serrations 830A. Further, it is noted that while less preferred, the
serrations may be
- 27 -
CA 02885428 2015-03-18
WO 2014/047466
PCT/US2013/060974
dispensed with since the substantial force of the bevel edges against one of
the inner surfaces
of sidewalls 826A or 826B will also resist such separation between the locking
engagement
members under load. In yet another alternative the inner surface may be
roughened or coated
with a non-slip material to resist slippage of the bevels.
[00126] Figure 22C generally corresponds to Figure 22A except that in this
embodiment
retaining clips are not used and panels 804A/806A abut the edges of panels
804B/806B.
[00127] In embodiments it is sometimes necessary to maintain a predetermined
spacing
between the bottom panels of interlocked panel units and the purlin or other
supporting
member to which the panel units are attached. For example, such spacing may be
required to
align the top surface of the upper panels of the panel units with side framing
members like
those of support frame 520 of Figure 13. Figures 23A and 23B illustrate an
important new
contribution to the design of retaining clips which makes it possible to
easily and efficiently
maintain such predetermined spacing.
[00128] As can be seen in Figures 23A and 23B the spacing maintained between
the
bottom surface of the lower panel unit panels and the purlin is determined by
the distance of
top lip surface 870 and seat surface 876 from the bottom 862 of the base and
the bottom
surface 882 of foot portion 880. Therefore, these distances may be adjusted in
forming
retaining clips of this design in order to accommodate different desired
spacings.
[00129] In Figure 22B, panel units 840 and 842 are shown with their locking
members
interlocked and a retaining clip 844 holding the panel units against a purlin
or other support
member (not shown). As in this and the various other locking member designs
described
earlier, panel expansion and contraction due to ambient temperature changes is
accommodated by generally lateral movement of the first member of a first
locking member
in the receiving cavity of the second locking member.
[00130] Thus, retaining clip 850 is shown in these figures engaging second
engagement
member 802 of panel unit 842 in Figure 23B. Retaining clip 850 includes a base
854 having
a bore 856 through which an appropriate fastener 858 is passed to attach the
base of the clip
to a supporting purlin 860. The base 862 of the clip rests directly onto the
top surface 864 of
the purlin.
[00131] Clip 850 includes an arm 866 that projects upwardly from base 854. A
lip 868
projects generally perpendicularly from the arm and has a top surface 870 that
is generally
parallel to surface 864 of the purlin.
- 28 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
[00132] The clip also includes an upstanding wall 872 along its front edge
with a hook 874
in engagement with T-shaped member 442 as shown. A clip seat portion 875
projects
generally perpendicularly from wall 872. The top surface 876 of the seat and
top surface 870
of lip 868 are coplanar so that they respectively support adjacent panels of
the interlocked
panel units at the same spacing from the purlin surface. Seat 876 includes a
leg 878 that
projects downwardly and generally perpendicularly from the seat. Finally, a
foot portion 880
projects generally perpendicularly forward from the leg. The bottom surface
882 of the foot
portion is coplanar with bottom surface 862 of base 854.
[00133] The modular panels 884 of Figure 27A and 27B are of a new design in
which
pairs of flanges or "dual flanges" 886A and 886B project from the inner
surface 888 of the
panels. This dual flange design offers advantages over capturing a single
panel flange (e.g.,
flange 12 in Figure 2) in a cavity (e.g., cavity 408 in Figure 11A) of a
locking engagement
member defined by a back wall (e.g., back wall 418 of Figure 11A) and a
cantilever arm
(e.g., member 426 of Figure 11A), since no flexure of an engagement member
cantilever arm
will be required. The dual flange panel design thus replaces the flexure
required of the
cantilever arm with flexure in the dual flanges which bend out of the way
during the
attachment to the locking engagement members and resile back to their initial
position to lock
the panels to the locking engagement members. By eliminating the requirement
of a flexible
cantilever arm with a length sufficient to provide a moment arm that will
ensure sufficient
flexure during attachment to a single panel flange, the engagement member arm
may be
reduced in length and provided with increased rigidity and ultimate tensile
strength. As a
result, the spacing between panels of a panel unit may be reduced. And, most
importantly,
since the engagement members may be constructed with higher tensile strength,
the span
between panel unit supports may be increased reducing the number of support
members and
clips required in a panel unit installation.
[00134] Additionally, the edges of the distal or outer flange of each pair of
dual flanges
may be spaced a distance "C" from the distal ends 892 of the panels or they
may be generally
coplanar with the panel ends (e.g., as in Figure 2B). Distance "C" should be
from about 0.5
to about 8 mm. Spacing the flange pairs from the distal ends in this way
exposes portions
894A and 894B of the panels which will have enhanced flexure and resilience as
a result of
this geometry to help accommodate lateral expansion and contraction of the
modular panels
in conjunction with their interlocking engagement members. The degree of
flexure may be
enhanced by removing the honeycomb structure in this resilient portion as in
resilient portion
894A or by reducing the thickness of the panel outer wall 893A or 893B along
resilient
portions 894A or 894B. The degree of flexure may also be enhanced by providing
an internal
structural wall 897 having a thickness generally equal to the thickness of the
panel outer wall
- 29 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
16 to further isolate the resilient portion thereby enhancing its resiliency.
As a result of the
enhanced flexure provided in these ways, when the resilient portions abut
during an
expansion phase, control of air, water and sound infiltration will be
enhanced. And, these
portions will compress laterally to avoid buckling of the panel under very
high lateral
expansion conditions.
[00135] Figure 27C depicts an alternate modular panel dual flange design in
which both
distal ends of the panels of the panel units and the distal portions of the
outer flanges are
structured to have enhanced flexure and resilience. In this alternative
structural design, panel
999 includes dual seam flanges in the form of a proximal or inner flange 1000
and a distal or
outer flange 1002. The outer surface 1004 of flange 1002 includes a notch 1006
so that the
bottom portion 1008 of the outer surface of flange 1002 is spaced from the
distal end 1010 of
panel 999 a distance of about 0.5 to 8 mm. This geometry produces flexure and
resilience
both at the distal end of the panel and at the outer surface of flange 1002.
[00136] Finally, facing inner edges 895A and 895B of the dual flanges each
have
corresponding sawteeth 896A and 896B defining a locking cavity 898 which will
be
addressed further below.
[00137] Locking engagement members 900 and 902 are constructed generally like
first
and second locking engagement members 402 and 404 of Figures 11A and 11B and
locking
engagement members 800 and 802 of Figures 22A-22C. However, as will be
discussed
below, locking engagement members 900 and 902 differ in their structure for
attachment to
the panel dual flanges and include optional additional gasketing.
[00138] Thus, first locking engagement member 900 includes a male member or
spine 912
that projects generally perpendicularly from the front surface 916 of back
wall 914. Spine
912 (as well as the spines of engagement members 32, 402 and 800) optionally
may be offset
from 90n at an angle sufficient to accommodate the angle between adjacent
panel units of
curved panel unit installations.
[00139] Spine 912 extends from back wall 916 to a pair of guide, pull-out, and
pivot
support "T"-shaped rails 918A and 918B which arc disposed generally
perpendicularly to the
rail with the outer faces 920A and 920B of the top of the "T" generally
parallel to the
corresponding surfaces of spine 912 to help guide the first locking engagement
member into
the interlock cavity 913 of the second locking engagement member and to abut
the inner
surfaces of the interlock cavity sidewalls.
- 30 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
[00140] Continuing along spine 912, at a distance "D" from T rails 918A and
918B, a pair
of generally flat catch rails 922A and 922B are located and oriented
perpendicularly to spine
912.
[00141] Interlock cavity 910 includes sidewalls 926A and 926B (Figure 27A) for
receiving
first member 908. Serrations 930 are formed along the inside surface of
sidewalls 926A and
926B. While two serrations are shown on sidewalls 926A and 926B in Figure 27A,
any
desired number may be used. And, as shown in Figure 27B the serrations may be
present on
the inside surface of only one of the walls.
[00142] Sidewalls 926A and 926B extend to their distal edges 932A/932B where
angled
walls 934A and 934B are present to facilitate the entrance of member 908 to
cavity 928.
[00143] Finally, an elastomeric gasket 936 optionally may be located along a
portion of
spine 912 distally to T rails 918A and 918B to seal against along the inner
surface of one of
the sidewalls when the locking engagement members are interlocked. Since
gasket(s) 936
extend upwardly and/or downwardly from the spine, when the spine enters
interlock cavity
913 of second locking engagement member 902 it will engage the opposed inner
surface of
the cavity wall to produce a supplemental seal. Alternatively, elastomeric
gaskets may be
located on both sides of spine 912.
[00144] Panels 884 are mounted in first locking engagement member 900 and a
pair of
panels 884 are mounted in second locking engagement member 902 to respectively
form
panel units 941A and 941B.
[00145] Elongated resilient gaskets 940A and 940B with locking engagement
members
942A at 942B having distal flexible arrow shapes may be mounted to cavities
944A and
944B in the engagement members. The gasket members are dimensioned so that
when the
locking engagement members are interlocked the gaskets will fill the space
between outer
surfaces 890A and 890B of the outer flanges of the lower (or inside) panels of
adjacent panel
units 941A and 941B while the inner surfaces 947A and 947B of the gaskets
press up against
each other (behind upstanding wall 961 of clip 960) and encapsulate the clip
wall to help
limit air, water and sound infiltration across the interlocked members.
Although the
elongated resilient gaskets are shown adjacent the lower panels of the panel
units, they may
also be included adjacent the upper panels of the panel units.
[00146] Locking engagement members 900 and 902 may include additional
gasketing
systems to further limit air, water and sound infiltration across the
interlocked locking
-31 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
engagement members. Thus, second locking engagement member 802 may include a
first
shelf member 915 bearing an upper resilient sealing member 917 having a series
of flexible
fingers 919 along its top surface and/or a series of flexible fingers 921
along its bottom
surface. The sealing member and fingers are positioned so that when the
locking engagement
members are interlocked, fingers 919 abut the bottom surfaces of the adjacent
panel seam
flanges and fingers 921 abut the opposed surface of a second shelf member 923
of first
locking engagement member 900 producing yet further sealing against air, water
and sound
infiltration across the interlocked members.
[00147] Figure 27B illustrates an alternative embodiment in which the first
and second
locking engagement members are designated respectively 908 and 910 and the
panels of the
adjacent panel units abut up against each other, so that, for example, there
is no space to
receive gaskets 940A and 940B of the Figure 27A embodiment. Therefore, in this
embodiment, gaskets 945A and 945B are used and both abut along their inner
surfaces and
also abut the top surface of the outer flanges of the dual flanges of the
lower panels of the
adjacent panel units.
[00148] An internal gutter 946 is formed in the emodiments of both Figures 27A
and 27B
to receive any water that infiltrates across the space 943 between adjacent
top panels of the
interlocked panel units (Figure 27A) or across the interstice 949 (Figure 27B)
where the
edges of the top panels of the panel units abut. Additionally, pressure
breaker chambers 950
and 952 are formed between T rails 918A and 918B and catch rails 922A and
922B.
[00149] Finally, locking engagement members 900/902 and 908/910 include
opposed
surfaces 951 and 953 from which sawtooth-shaped latch members 954 project. In
the
illustrated embodiment of Figure 27A and 27B, the latch members have two
oppositely
directed pairs of sawteeth 956A and 956B along their opposite edges to form a
pine-tree
shape. As few as a single pair of oppositely directed sawteeth may be used, as
shown in
Figure 29, or greater than two pairs of oppositely directed sawteeth may be
used.
[00150] Assembly of panel units may proceed by placing panels 884 on a support
surface
with dual flanges 890A and 890B projecting upwardly and inserting latch
members 954 into
the locking cavities of the dual flanges. As pressure is applied, the flanges
of the flange pairs
will resile outwardly and then snap back into position once the latch members
are fully seated
in the cavities with the corresponding sawteeth of the locking engagement
member and the
flanges engaged. Once this is completed at both lateral edges of the panel, a
second, top
panel is applied by locating its flange cavities opposite the top latch
members and pressing
downwardly, again causing the flanges to resile and snap back into place as
described above.
- 32 -
CA 02885428 2015-03-18
WO 2014/047466 PCT/US2013/060974
[00151] Locking clip 960 is shown in the embodiment of Figure 27A with spacer
legs 962
and 964, shelf members 963 and 965, and feet 966 and 967 which rest against
the bottom
panel surface (foot 967 and shelf 963) and a purlin or other supporting
framing (foot 966 and
shelf 965). This clip structure maintains a spacing between the panel units
and the support
framing for example as described above with respect to Figure 14.
[00152] Turning now to Figure 28, modular panels 948 with paired upstanding
flanges
970A and 970B are shown. In this embodiment, the inner surfaces 972 of the
distal flanges
are coplanar with the lateral ends 974 of the panels. The outer flange of the
dual flanges may,
however, be spaced from the panel ends as shown in Figures 27A, if desired.
[00153] As can be seen in this Figure 28, distal flanges 970B include sawteeth
976
whereas proximal or inner flanges 970A have a generally flat surface 978
forming a locking
cavity 980 with sawteeth along one side only. This design may be reversed as
required so
that the outer flanges include the sawteeth. Latch members 982 in this figure
differ from
latch members 954 in Figures 27A-27B in that the latch members have a
generally flat back
surface 984 and sawteeth 986 along their opposite surface. Thus, when it is
desired to
interconnect panel units, the procedure described above may again be used to
insert and lock
the latchmembers into the locking cavities of the dual flanges.
[00154] Figure 29 shows yet another modular panel embodiment 988 with paired
upstanding flanges 990A and 990B. In this embodiment, latch member 992 of
first and
second locking engagement members 989 and 991 has but a single sawtooth 994
which
projects into the locking cavity 994 between the pair of flanges 996A and 996B
to engage a
single sawtooth 998 located on the inner surface of the distal flanges.
[00155] Finally, Figure 24 depicts a pair of fiberglas sandwich panels 1400
and 1402. The
sandwich panels each include top panels 1404 and bottom panels 1406. Although
the top and
bottom panels are shown to be of the same thickness in this figure, a thinner
lower panel may
suffice in many applications due to the structural integrity provided by the
metal locking
engagement members. Also, while the panels are referred to as being made of
fiberglas,
panels made of other transparent or translucent resins may be used.
[00156] Sandwich panels 1400 and 1402 are provided with corresponding first
and second
metal locking rails 1408 and 1410 adjacent the lateral edges 1413 and 1415 of
the panels.
The locking rails are generally "I-beam" shaped and include top and bottom
shelf supports
1412 and 1414 which are adhered to the inner surfaces 1416 and 1418 of the top
and bottom
- 33 -
CA 02885428 2015-03-18
WO 2014/047466
PCT/US2013/060974
panels by way of an appropriate adhesive located in the interstices 420 and
422 between inner
surfaces 416/418 and top and bottom shelf supports 1412/1414.
[00157] Corresponding first and second locking engagement members 1424 and
1426 are
located generally midway along rails 1408 and 1410. The rails are oriented so
that the first
and second locking engagement members project away from the panels. As shown,
in Figure
24 the second locking engagement member is generally U shaped and includes an
inner
cavity 1427 and outwardly projected lips 1428 which help guide the first
locking engagement
member into the second locking engagement member. The first locking engagement
member, in turn, includes an upstanding rail 1430, an end flange 1432, with an
inwardly
directed lip 1434. As is apparent from this figure, when the adjacent sandwich
panels are to
be assembled, they are moved together so that the second locking engagement
member
receives the first locking engagement member in locking engagement. And, by
assembling a
series of sandwich panels together in this way on an appropriate support, a
transparent or
translucent architectural structure may be quickly and efficiently
constructed.
[00158] While Figure 24 illustrates first and second locking engagement member
pair
embodiments, any of the guide members and engaging cavity designs of the
locking
engagement members as illustrated in the earlier Figures and described above
may be used in
place of locking engagement members 424 and 426.
[00159] Figure 25
depicts a pair of laterally disposed sandwich panels 1436 and 1438 in
which the lateral edges 1413 and 1415 of the top and bottom fiberglas panels
1404 and 1406
are captured in first and second metal locking rails 1444 and 1446 where each
of these
locking rails includes an inner panel support member 1448 with top and bottom
shelf
supports 1450 and 1452. Although the shelf supports may be adhered to the
inner surfaces
1416 and 1418 of the top and bottom resin panels, preferably they are not
adhered. Rather,
the lateral edges of the panels are captured between the outer surfaces 1454
and 1456 of the
top and bottom shelf supports and flanges 1458 and 1460 of first and second
outer support
members 1462 and 1464. The flanges each include an interior cavity 1466 which
enables the
outer rails to be pressed home against the inner rails trapping the lateral
edges of the panels in
the space 1468 between the outer surfaces of the inner rails and the inner
surfaces 1470 and
1472 of flanges 1458 and 1460.
[00160] Corresponding first and second locking engagement members 1480 and
1482 are
located generally midway along outer support members 1462 and 1464. As can be
seen in
Figure 25, these first and second locking engagement members generally
correspond to
locking engagement members 1424 and 1426 of Figure 24 except that locking
engagement
- 34 -
member 1482 is provided with a resilient member 1486 at the bottom of cavity
1484 of this
locking engagement member.
[00161] Optional compressible gaskets 1488 may be positioned at opposite ends
of outer
rails 1462 and 1464, above flanges 1458 and 1460. These gaskets are made of an
elastic
material such as a synthetic rubber and are held in place by locking
engagement members
1490 which hook into cavities 1492.
[00162] Outer support members 1462 and 1464 are provided with upwardly opening
flanges 1496 and 1498. Similar upwardly opening flanges to receive retention
clips may be
provided along the inner edge of rails 1408 and 1410 of Figure 24. Flanges
1496 and 1498
are to be used in conjunction with metal retention clips 1500 which are
designed and
function much the same as retention clips 34 described earlier.
[00163] Retention clips 1500 include a base 1506 with a hole for receiving a
fastener 1508
which will be driven or screwed into a purlin, rafter or other support to hold
adjoining
sandwich panels in place. The clips also include an upstanding wall 1502 and
an engagement
hook 1504 which is dimensioned to engage flange 1596. Thus, this retention
clip can be used
to fix sandwich panel 1438 in place during the onsite erection of glazing,
skylights, roofs,
walls, etc. whereupon sandwich panel 1436 can be laterally aligned as shown
and moved
into place so the first and second locking engagement members engage and the
end flange
1494 of locking engagement member 1480 will compress resilient member 1486 at
the
bottom of cavity 1484 forming an air and water resistant seal at that point
and gaskets 1488
will abut forming air and water resistant seals along the gaskets between the
adjacent
sandwich panels. This final construction is illustrated in Figure 24.
[00164] Installation of the adjacent panels of Figures 24 and 25 may proceed
generally as
discussed above.
[00165] The use of the terms "a" and "an" and "the" and similar referents in
the context of
describing embodiments to be construed to cover both the singular and the
plural, unless
otherwise indicated herein or clearly contradicted by context. Recitation of
ranges of values
herein are merely intended to serve as a shorthand method of referring
individually to each
- 35 -
CA 2885428 2018-10-18
separate value falling within the range, unless otherwise indicated herein,
and each separate
value is incorporated into the specification as if it were individually
recited herein. All
methods described herein can be performed in any suitable order unless
otherwise indicated
herein or otherwise clearly contradicted by context. The use of any and all
examples, or
exemplary language (e.g., "such as") provided herein, is intended merely to
better illuminate
embodiments does not pose a limitation on the scope of the invention unless
otherwise
claimed.
[00166] Finally, it should be understood that the illustrated embodiments are
exemplary
only, and should not be taken as limiting the scope of the invention.
- 36 -
CA 2885428 2018-10-18
