Abstract:
A wall mounted panel system wherein panels are permitted three directions of expansion and contraction since each of panel is affixed to the wall at a single point. For example, the system includes a first and second panel adjacent to one another. An upper bracket and a lower bracket are affixed to the back of each panel, wherein the upper brackets are affixed to the wall and wherein the lower bracket of the first panel is movably engaged with the upper bracket of the second panel. The panels do not communicate with any sealing members, thereby allowing for air to flow freely behind the panels for providing a means of removing moisture from behind the panels. A brace member in communication with the interior surface of each panel has an upper end affixed to the upper bracket and a lower end affixed to the lower bracket.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the priority of U.S. Provisional Patent Application No. 61/167,457 entitled “RAINSCREEN ATTACHMENT SYSTEM,” filed Apr. 7, 2009, the contents of which are hereby incorporated by reference. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    This invention was made with government support under grant number SBAHQ-05-I-0061 awarded by the U.S. Small Business Administration. The government has certain rights in the invention. 
     
    
       [0003]    FIELD OF THE INVENTION 
         [0004]    A novel method of attaching building façade panels to the exterior of buildings to create a drained/back-ventilated rainscreen. More particularly, the invention consists of a series of brackets and panel configurations that allow the panels to be attached easily, allow airflow behind the panels, allow for the thermal expansion and contraction of the panels, allow for guttering of water, and reduce the labor and material requirements when compared to existing systems. 
       BACKGROUND OF THE INVENTION 
       [0005]    Current aluminum composite material (ACM) panel attachment methods are labor intensive and require a large amount of aluminum extrusions. This makes the overall system costly when compared to other building siding materials. Also, most current systems are designed to be water-tight by means of rubber seals and/or caulking. A water-tight system is difficult to achieve in practice and does not allow for the removal of moisture trapped in the interior of the panels. 
         [0006]    ACM panels are typically spaced between ⅜ and ¾ inches apart for aesthetics and to allow for the thermal expansion of the panels. Existing ACM systems use caulking, aluminum extrusions, or additional pieces of ACM (referred to as reveal strips) to fill in the joint gap between the panels. 
       SUMMARY OF THE INVENTION 
       [0007]    The invention is a method and apparatus for attaching panels, e.g., aluminum composite material (ACM) panels, to the exterior of buildings to create a drained/back-ventilated rainscreen. The system is based on the Drained/Back Ventilated (D/B-V) Rainscreen principle. The system will allow air to flow freely behind the panels, thereby providing a means of removing moisture from the interior of the panels. The system will allow some water penetration, but will control this water using a guttering network. The system consists of a series of interlocking brackets and panel configurations that allow the panels to be attached easily, allow airflow behind the panels, allow for the thermal expansion and contraction of the panels, allow for guttering of water, and reduce the labor and material requirements when compared to existing systems. 
         [0008]    By creating a novel panel configuration that allows the panels to overlap, the Improved Rainscreen Attachment System (IRAS) eliminates the need to fill the gap between panels with additional components. In the system of the invention, the reveal strip is integrated into the right side of a left panel. The reveal strip is formed from the ACM and therefore requires no additional painting or means of fastening. Standard hat furring channel, a very common building material, is located behind the joint gap and serves as an inexpensive means of guttering in the vertical direction any water that penetrates the vertical joint as well as water that has been channeled there by the horizontal joint guttering system. 
         [0009]    In the improved rainscreen attachment system of the invention, guttering in the horizontal direction is achieved by a channel that is formed out of panel material and is an integral part of the panel. Again, because the channel is integrated into the panel, the channel requires no additional painting or means of fastening. The horizontal joint prevents rainwater from getting behind the panels yet allows for air to flow freely in behind the panels. This air flow provides a means of removing moisture from the inside of the panels. 
         [0010]    The joints also allow the bottom of each panel to float up or down or from side to side to compensate for the thermal expansion and contraction of the panels. Without this feature the panel edges would be fixed and the panels would tend to bow (referred to as “pillowing”) as the panels thermally expand. In the current system, only the top of each panel is fixed, while the other three sides are allowed to float. If deemed necessary, the top of each panel could also be designed to have some limited amount of float. This would be accomplished by simply slotting the mounting holes in the top brackets and using shouldered bolts to attach the brackets to the external sheathing. 
         [0011]    Upper brackets provide a rigid framework for the gutter section of the ACM. The upper brackets also serve as the means of attaching the panel to the wall and create a gap, e.g., 1 inch, between the panel and the wall to allow for adequate airflow between the wall and the panel. 
         [0012]    Bottom brackets are provided of varying lengths depending on whether a long or short joint gap is desired. The bottom bracket allows the bottom of the panel to hook onto the top of the previously placed panel. The bottom bracket may be only 3 inches wide, a continuous extrusion nearly equal in length to the width of the panel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is an elevation view of the panel system of the invention; 
           [0014]      FIG. 2  is a top view of the panel system of  FIG. 1  taken along lines  2 - 2  of  FIG. 1 ; 
           [0015]      FIG. 3  is a rear elevation view of one of the panels of the panel system of  FIG. 1 ; 
           [0016]      FIG. 4  is a side view of one of the panels of the panel system of  FIG. 1 , taken along lines  4 - 4  of  FIG. 3 ; 
           [0017]      FIG. 5  is a side view of the panel of  FIG. 4  shown assembled with other panels; 
           [0018]      FIG. 6  is an enlarged view of a top of one panel and a bottom of a second panel of the panel system of  FIG. 1  and showing the interlocking configuration of the first and second panels in partial phantom lines; 
           [0019]      FIG. 7  is an enlarged perspective view of a bottom clip of the panel system of  FIG. 1 ; 
           [0020]      FIG. 8  is an enlarged perspective view of a top clip of the panel system of  FIG. 1 ; 
           [0021]      FIG. 9  is a perspective view of an alternate embodiment of the panel system; 
           [0022]      FIG. 10  is a top view of the panel system of  FIG. 9 ; and 
           [0023]      FIG. 11  is a rear perspective view of a panel interior of the panel system of  FIG. 9 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0024]    A wall mounted panel system designated generally  10  comprises a plurality of panels  12 . A plurality of panels  12 , for example first panel  14 , second panel  16 , third panel  18 , fourth panel  20 . Hat channels  21  are affixed to a wall surface  23  behind panels  12 . Hat channels  21  are located behind a joint gap formed by adjacent panels and functions as a vertical gutter for any water that may migrate behind the panels. First panel  14  includes a main vertical member  22  having a top edge  24 , right edge  26 , left edge  28 , and bottom edge  30 . Panels  12  are preferably constructed of a composite aluminum skin bonded to a polyethylene core. The aluminum skin material may be machined from one side to facilitate bending of the material, e.g., to create edges  24 ,  26 ,  28 , and  30 . 
         [0025]    Top member  32  ( FIGS. 4 ,  5 ) has an inside surface and an outside surface. Top member  32  and main vertical member  22  have an inside surface that defines a first recess  34  ( FIGS. 4-6 ) and a second recess  36  (not shown) where members  22  and  32  join, i.e., wherein the metallic skin and a portion of the core material is removed to create a recess for receiving a protrusion of an upper bracket. Top member  32  extends rearwardly from top edge  24  of main vertical member  22 . Top member  32  has an upper vertical flange member  38  that protrudes upwardly therefrom. Upper vertical flange member  38  has a right end  40  that extends a distance to the right of right edge  26  of main vertical member  22 . 
         [0026]    An uppermost horizontal member  42  ( FIGS. 1 ,  3 ,  4 ,  6 ) extends forwardly from a top edge of upper vertical flange member  38 . Uppermost horizontal member  42  preferably has a width equal to a width of main vertical member  22 . Top member  32 , vertical flange member  38 , and uppermost horizontal member  42  form a channel or horizontal gutter that directs water horizontally. 
         [0027]    Bottom member  44  has an outside surface and an inside surface. Bottom member  44  defines a first recess  46  and a second recess  48  machined on the inside surface, i.e., wherein the metallic skin and a portion of the core material is removed to create a recess for receiving a protrusion of a bottom bracket. 
         [0028]    Right member  50  ( FIGS. 1 ,  3 ) extends rearwardly away from right edge  26  of main vertical member  22 . Right member  50  has a right vertical flange member  52  that protrudes therefrom to a distance equal to the distance of upper vertical flange member  38  extends to the right of right edge  26  of main vertical member  22 . An upper end of right vertical flange member  38  is inserted behind the right end  40  of upper vertical flange member  38 , thereby creating a shingle-like overlap to deter an influx of water behind panel system  10 . 
         [0029]    Right border flange member  54  is affixed to an outer edge of the right vertical flange member  52 . Right border flange member  54  extends in a rearward direction from the right vertical flange member  52 . 
         [0030]    Left member  56  extends rearwardly from left edge  28  of main vertical member  22 . A first upper bracket  58  has a forward upwardly extending member  60  and a rearward upwardly extending member  62  separated by upper horizontal member  64 . Rearward upwardly extending member  62  defines a first mounting orifice  66 . Forward upwardly extending member  60 , rearward upwardly extending member  62 , and an upper surface of upper horizontal member  64  define an upwardly facing channel  68 . First upper bracket  58  further defines a lower downwardly extending member  70  and a lower horizontal member  72  wherein a lower surface of upper horizontal member  64  engages an upper surface of uppermost horizontal member  42 . Lower horizontal member  72  engages a lower surface of top member  32  (see, e.g.,  FIG. 6 ). 
         [0031]    First brace member  74  ( FIG. 3 ) has a first end  76 , a second end  78 , base  80  ( FIGS. 4 ,  5 ), and a top surface  82 . Base  80  is in contact with a rear surface of main vertical member  22 . The top surface  82  of first end  78  is affixed to the lower vertical downwardly extending member  70  of first upper bracket  58 . 
         [0032]    A second upper bracket  84  has a forward upwardly extending member  86  and a rearward upwardly extending member  88  separated by an upper horizontal member (not shown). Rearward upwardly extending member  88  defines second mounting orifice  92 . Forward upwardly extending member  86 , rearward upwardly extending member  88 , and an upper surface of the upper horizontal member define an upwardly facing channel similar to upwardly facing channel  68  of first upper bracket  58 . Second upper bracket  84  further defines a lower downwardly extending member  96  and a lower horizontal member similar to lower horizontal member  72  of first upper bracket  58 . A lower surface of the upper horizontal member engages an upper surface of uppermost horizontal member  42 . The lower horizontal member engages a lower surface of top member  32 . 
         [0033]    Second brace member  100  has a first end  102 , a second end  104 , a base, and a top surface  108 . The base is in contact with a rear surface of main vertical member  22 . Top surface  108  of second end  104  is affixed to lower downwardly extending member  96  of second upper bracket  84 . First brace member  74  and second brace member  100  are preferably affixed to an inside of main vertical member  22  with a structural silicon or other adhesive. Brace members  74  and  100  function as stiffeners that distribute load to wall  23  rather than through panel  12 , thereby allowing panel system  10  to meet high wind load standards. 
         [0034]    Referring now primarily to  FIGS. 4 and 6 , first lower bracket  110  has a base surface  112  affixed to a rear surface of main vertical member  22 . First lower bracket  110  further defines an upper horizontal member  114  and upper upwardly extending vertical member  116  that extends from a rearward edge of upward horizontal member  114 . First lower bracket  110  additionally defines a downwardly extending vertical member  118  that defines a receiving space  120  between downwardly extending vertical member  118  and base surface  112 . First lower bracket  110  further defines lower horizontal surface  122  for engaging an inside surface of bottom member  44 . 
         [0035]    Second end  78  of first brace member  74  contacts an upper surface of bottom member  44 . 
         [0036]    Second lower bracket  124  has a base surface affixed to the rear surface of main vertical member  22 . Second lower bracket  124  further defines upper horizontal member and upwardly extending vertical member  130  that extends from a rearward edge of upper horizontal member  128 . Second lower bracket  124  additionally defines downwardly extending vertical member that defines receiving space between the downwardly extending vertical member and base surface  126 . Second lower bracket  124  further defines lower horizontal surface  136  for engaging inside surface of bottom member  44 . 
         [0037]    Second end  104  of second brace member  100  contacts an upper surface of bottom member  44 . 
         [0038]    Although first panel  12  was discussed above, it should be understood that second panel  14 , third panel  16 , and fourth panel  18  share similar components that will share the numerical designations of counterpart components from panel  12 . 
         [0039]    Wall mounted panel system  10  additionally includes second panel  16  that may be installed above first panel  14  ( FIG. 1 ) by locating downwardly extending vertical member  118  of first lower bracket  110  of second panel  16  into upwardly facing channel  68  of first upper bracket  58  of first panel  14 . Additionally, downwardly extending vertical member  132  of second lower bracket  124  of second panel  16  is located in upwardly facing channel  94  of second upper bracket  84  of first panel  14 . The interface between upper brackets  58 ,  84  of first panel  14  and lower brackets  110 ,  124  of second panel  16  allow for relative movements between panels  14  and  16 . Each of panels  12 ,  14 ,  16 , and  18  are affixed to a wall surface at first mounting orifice  66  and second mounting orifice  92 , thereby permitting three directions of expansion and contraction. 
         [0040]    Wherein space  138  between first panel  14  and second panel  16  is occupied by upper vertical flange member  38  of second panel  16 . 
         [0041]    Additionally, third panel  18  may be installed adjacent to first panel  14 . Wherein space  140  between first panel  14  and third panel  18  is occupied by right vertical flange member  52 . The integrated upper flange member  38  and right vertical flange member  52  provide coverage between panels  12 , i.e., form integral reveal strips, thereby ensuring consistency in color and a relation in components of panel system  10 . 
         [0042]    Referring now to  FIGS. 9-12 , shown is an alternate embodiment  200  of the panel system of the invention, which shares some components of the previously discussed system  10 . System  200  utilizes panels  202  having a main vertical member  222 . Panels  202  have a top member  232  having an inside surface and an outside surface. Top member  232  extends rearwardly from top edge  224  of main vertical member  222 . Top member  232  has an upper vertical flange member  238  that protrudes upwardly therefrom. Bottom member  244 , right member  250  and left member  256  extend rearwardly from main vertical member  222  (see  FIG. 11 ). 
         [0043]    Panels  202  are affixed to a wall surface  23  in the same manner as wall system  10 , discussed above. Embodiment  200 , however, utilizes a modified hat channel  221  that provides an integral reveal strip  223 , thereby eliminating a need for panels  202  to have integral flange members between side by side adjacent panels. In this embodiment of the invention, upper vertical flange members  238  ( FIG. 11 ) occupy the space in between above and below adjacent panels  202 . 
         [0044]    Three brace members  282  are shown affixed to a rear surface of main vertical member  222 . However, greater than three or less than three brace members  282  may be utilized as conditions warrant. 
         [0045]    The panel system of the invention is advantageous in that the system presents clean lines for an improved aesthetic appearance. The wall attachment methodology and interlocking brackets that allow relative movement between panels ensures that three-directional movement is facilitated to accommodate thermal expansion and other forces. The shingled jointery created by overlapping surfaces functions to minimize water penetration and to eliminate the necessity for gaskets and sealants between adjacent panels. The panel system of the invention eliminates a requirement for affixing a framework to a wall surface to receive panels, since each panel is affixed to the wall surface via upper brackets. As can be seen in  FIG. 6 , the interlocking panels of the invention facilitate air flow behind the panels to effect the drying of water that has migrated behind the panels. 
         [0046]    Thus, the present invention is well adapted to carry out the objectives and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed within the spirit of this invention as defined by the claims.