Abstract:
A composite wall system is provided that employs a single thermally efficient edge extrusion. The present composite wall system does not use sealant at panel joints, is relatively lighter, and experiences substantially little to no thermal bridging found in conventional systems. It provides for an adjustable attachment system to allow panels to be adjusted to maintain optimal spacing along the panel margins and panel seal.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is related to and claims priority from earlier filed U.S. Provisional Patent Application No. 62/253,359, filed Nov. 10, 2015. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to a unitized/panelized wall system and the joints utilized therein. More specifically, the present invention relates to a modular wall construction system that facilitates assembly of unitized wall panels in the shop having a unique interfitting panel joint that facilitates reduced erection and assembly labor in the field. 
         [0003]    Architectural panels, such as utilized in exterior building envelope construction, have been in use for a number of years. Conventional exterior building envelope construction can be categorized into three basic construction categories: (1) stick-built construction, (2) unitized curtain wall construction, and (3) panelized wall construction. 
         [0004]    Stick-built construction is a relatively old technology. In stick-built construction, a structure is assembled piece-by-piece at a worksite, with little or no prefabrication of the structure into subassemblies prior to delivery of the construction materials to the site. For example, conventional residential/commercial utilize stick-built construction techniques. Conventional stick-built construction can provide a number of benefits. For example stick-built construction is adaptable to customization, relies on the talent of the craftsmen, and is substantially weather dependent in nature. 
         [0005]    Unitized curtain wall construction has been in use over the last half-century. Conventional unitized curtain wall assemblies include a combination of glass, mullions, and gaskets, where the glass and aluminum mullions are prefabricated (e.g., shop assembled) offsite. Conventional unitized curtain wall construction can provide a number of benefits. For example, because the assemblies are typically manufactured in a controlled environment (i.e., within a shop rather than on-site), unitized curtain wall construction techniques provide relatively high-quality assemblies. 
         [0006]    Panelized wall construction has been in use over the last two decades. Conventional panelized wall construction has replaced some of the stick-built construction in certain scenarios, such as in brick walls, metal panel walls, and corrugated metal walls, for example. Conventional panelized wall assemblies are typically utilized in cases where a wall is not required to be configured as an all-glass wall type. The design includes conventional design components such as heavy structural steel, light gage meal framing, sheathing, air-and-vapor barrier sheets, insulation, sub-girts, and sealant, for example. 
         [0007]    Conventional exterior building envelope construction techniques suffer from a variety of deficiencies. For example, stick-built construction is relatively slow and costly to build, and can have variable quality control issues. For unitized curtain wall construction, due to the fundamental basis of the design, conventional unitized curtain wall assemblies typically include a relatively low (i.e., poor) R-Value, such as an effective R-Value of between about 1 and 3, which is due to thermal bridging through aluminum ‘box’ mullions. Further, conventional unitized curtain wall constructions are limited in sizes to approximately five feet (5′) in width. 
         [0008]    For panelized wall construction, due to the fundamental basis of the design, conventional panelized wall assemblies include sub-girts having relatively poor thermal bridging (e.g., per ASHREA) and sealant uses at transition joints which requires maintenance, for example. Further, conventional panelized wall assemblies are relatively heavy, have a relatively thick wall depth (12″ to 18″), a relatively low (i.e., poor) R-Value, such as an effective R-Value of between about 4 and 12. Effectively, the panelized wall construction is the same construction method as conventional stick-built constructions. However, panelized wall assemblies are manufactured in a controlled environment, rather than on-site. This provides relatively higher quality, yet relatively poor performance. 
         [0009]    By contrast to conventional exterior building envelope construction techniques, embodiments of the present innovation relate to a unitized wall panel assembly. In one arrangement, the unitized wall panel assembly is a composite wall system configured to distribute and transfer loads, such as wind loads, through a composite action between the unitized wall panels and the studs of the assembly. Further, the joint design of the composite wall system provides an increase in thermal performance compared to conventional system. For example, the unitized wall panel assembly provides a substantially large thermal R-Value (e.g., an effective R-Value of about 19 or more per ASHREA) for about half the wall depth of conventional panel wall systems. The design is based upon the interaction among an insulated wall panel, thermally efficient joints, and the finish cladding, such as specified by an architect. 
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    In this regard, the present invention provides a unitized wall panel assembly that consists of a composite wall system configured to distribute and transfer loads, such as wind loads, through a composite action between the unitized wall panels and the studs of the assembly. Further, the joint design of the composite wall system provides an increase in thermal performance compared to conventional system. 
         [0011]    In accordance with the present invention a unitized wall panel assembly construction provides benefits relative to the aforementioned construction types. For example, the conventional unitized curtain wall systems rely on, as a minimum, a two-piece extrusion to capture glass and transfer design load. By contrast the present composite wall system uses a single thermally efficient extrusion. Further, the conventional unitized curtain wall systems are not designed to allow attachment of brick or other exterior veneer to attach to it, contrary to the present composite wall system. 
         [0012]    In another example, the panelized wall system relies on sealant at the joint locations which require maintenance, are heavy, expose the associated insulation to the weather and elements, and function poorly from a thermal standpoint. By contrast, the present composite wall system does not use sealant at panel joints, is relatively lighter, and experiences substantially little to no thermal bridging found in conventional systems. 
         [0013]    It is therefore an object of the present invention to provide a panelized wall system that includes an integrated edge sealing joint to eliminate the need for sealant at the panel joints. It is a further object of the present invention to provide a panelized wall system that includes an adjustable mounting system that facilitates ease of installation and an ability to adjust the panel positions relative to one another in order to optimize the performance of the integrated edge sealing joint. 
         [0014]    These together with other objects of the invention, along with various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed hereto and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated a preferred embodiment of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    In the drawings which illustrate the best mode presently contemplated for carrying out the present invention: 
           [0016]      FIG. 1  illustrates a side sectional view of a wall panel construction in accordance with the present disclosure; 
           [0017]      FIG. 2  illustrates an edge joint detail showing a panel joint in accordance with the wall panel construction of the present disclosure; 
           [0018]      FIG. 3  illustrates a top sectional view of a wall panel construction in accordance with the present disclosure; 
           [0019]      FIG. 4  illustrates a side sectional view of an alternate arrangement wall panel construction in accordance with the present disclosure; 
           [0020]      FIG. 5  illustrates a side sectional view of an alternate mounting arrangement for a wall panel construction in accordance with the present disclosure; and 
           [0021]      FIG. 6  depicts an edge detail for a wall panel construction in accordance with the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]    Now referring to the drawings, embodiments of the present innovation are disclosed that relate to a unitized wall panel assembly. In one arrangement, the unitized wall panel assembly is a composite wall system configured to distribute and transfer loads, such as wind loads, through a composite action between the unitized wall panels and the studs of the assembly. Further, the joint design of the composite wall system provides an increase in thermal performance compared to conventional system. For example, the unitized wall panel assembly provides a substantially large thermal R-Value (e.g., an effective R-Value of about 19 or more per ASHREA) for about half the wall depth of conventional panel wall systems. The design is based upon the interaction among an insulated wall panel, thermally efficient joints, and the finish cladding, such as specified by an architect. Accordingly, the composite wall system provide relatively high strength with a smaller wall depth, less weight, and an increase in thermally efficiency compared to conventional construction methods. 
         [0023]    Conventional wall panels in the prior art are configured to be disposed on an exterior of a building, such as part of an external façade. The wall panel is typically configured as a substantially rectangular structure defining a longitudinal axis. In one arrangement, the panel is constructed from a foam insulation material, such as a substantially continuous polyisocyanurate insulation material with varying thicknesses. In one arrangement, the wall panel is configured to interlock with adjacently disposed panels to form a substantially continuous insulating structure. Opposing edges of a wall panel define an interlocking splined structure. 
         [0024]    In a conventional installation of the wall panels at a work site, studs, such as six inch C-studs, extend vertically relative to a structure. During an assembly procedure, an assembler typically disposes a wall panel relative to the studs such that the longitudinal axis of each panel is substantially perpendicular to the longitudinal axis of each stud. The assembler then secures the wall panel to each of the studs using a fastener and interlocks a subsequent wall panel with the splined structure of the previously secured wall panel. 
         [0025]    This conventional layout of the wall panels relative to the studs provides insulation to a building structure. However, such a layout suffers from a variety of deficiencies. For example, when exposed to a wind load, the insulated wall panels do not assist in composite action with that of the studs in transferring the load. Based upon the multipoint connections between the wall panels and studs, when exposed to a loading (e.g., a loading substantially perpendicular to the face of the wall panels, such as caused by the wind) the wall panels transfer the load to the studs. 
         [0026]    By contrast,  FIG. 1  illustrates an example of a composite wall system  100 , according to one arrangement of the innovation. The system  100  is configured to allow the mounting of insulated wall panels  100  in a unitized configuration to an edge-of-slab condition. In such an arrangement, each of the wall panels  100  can span a distance floor-to-floor without requiring any additional support framing. 
         [0027]    For example, the system  100  includes a set of panels  110  and a set of studs  120 . Each panel of the set  110  is configured as an insulated panel having an interlocking or splined structure formed at the joint  117  between edges  114 ,  116  of adjacent panels  110 . The wall panels  110  are disposed such that the longitudinal axis of each panel  110  is substantially parallel to the longitudinal axis of each stud  120 . The edge material at a joint  117  of two adjacent wall panels  110  is coupled to a corresponding stud  122  along the longitudinal axis of the stud. An example of such coupling using fasteners  125  is shown in  FIG. 2 . 
         [0028]    Attachment of the horizontal panel-to-panel joints  117  to the relatively light gauge metal stud  120  combines the strength of both the wall panels  110  and the studs  120  so that they act as a composite structure to support and transfer loads. For example, based upon the longitudinal connections between the wall panels  110  and studs  120 , when exposed to a loading (e.g., a loading substantially perpendicular to the face of the wall panels  110 , such as caused by the wind) the combination of the wall panels  110  and the studs  120  act to absorb the loading. Additionally, the positioning of the longitudinal axis  112  of the wall panels  110  substantially parallel to the longitudinal axis  122  of the studs  120  minimizes external loading (e.g., a wind load). 
         [0029]    Further, the composite wall system is configured to provide a substantially large thermal R-Value (e.g., an effective R-Value of about 19 or more per ASHREA) for about half the wall depth of conventional panel wall systems. 
         [0030]    Turning back to  FIG. 1 , in one arrangement, the wall panel  110  can include an extrusion assembly that extends around at least a portion of wall panel perimeter. For example, a wall panel can be configured with opposing extrusion assemblies on the panel&#39;s top and bottom edges (i.e. horizontal extrusions), on the panel&#39;s right and left side edges (vertical extrusions), or with an extrusion assembly  200  extending around the entire perimeter of the wall panel  110  (vertical and horizontal extrusions), as illustrated in  FIGS. 1 and 3 . In each case, the extrusion assembly  200  is configured to provide ease of assembly of the wall panels  110  in the field and to allow relative movement of the wall panels  110  once installed on a structure. 
         [0031]    As can be seen the wall panels  110  each having horizontal extrusions  200 - 1 ,  200 - 2  extending along opposing top and bottom edges. The extrusions  200 - 1 ,  200 - 2  are configured to allow mounting of panels  110  to a wall which allows relative horizontal and vertical movements between adjacent panels  110 . While the horizontal extrusions  200 - 1 ,  200 - 2  can be configured in a variety of ways, in one arrangement, the first wall panel  110 - 1  includes a first extrusion  200 - 1  disposed on a top edge where the first extrusion  200 - 1  includes a male component  202  which extends along the length of the wall panel  110 - 1 . Further, the second wall panel  110 - 2  includes a second extrusion  200 - 2  disposed on a bottom edge where the second extrusion  200 - 2  defines a channel or female component  204  which extends along the length of the wall panel  110 - 2 . Interconnection of the male and female components of the first and second extrusions  200 - 1 ,  200 - 2  couples the opposing wall panels  110 - 1 ,  110 - 2  to each other. When interconnected, the extrusions  200 - 1 ,  200 - 2  define a space or gap  206  between opposing wall panels  110 - 1 ,  110 - 2  of between about zero inches and  1 . 5   6  inches. This separation gap  206  isolates the wall panels  110 - 1 ,  110 - 2  from a building or structure  300  and allows for horizontal and vertical building movements while maintaining the integrity of the insulated wall panels  110 - 1 ,  110 - 2  as well as the building envelope&#39;s air, vapor, and weather barriers. 
         [0032]      FIG. 6  illustrates a top sectional view of adjacent wall panels  110 - 3 ,  110 - 4 , each having a vertical extruded perimeter  200 - 3 ,  200 - 4 , according to one arrangement. As illustrated, the extruded perimeter  200 - 3  defines a channel of female component  208  while the extruded perimeter  200 - 4  includes a male component  210 . When interconnected, the extrusions  200 - 3 ,  200 - 4  define a space or gap  212  between opposing wall panels  110 - 3 ,  110 - 4  of between about zero inches and 6 inches. This separation gap  212  isolates the wall panels  110 - 3 ,  110 - 4  from the building or structure  300  and allows for vertical building movement while maintaining the integrity of the insulated wall panels  110 - 3 ,  110 - 4  as well as the building envelope&#39;s air, vapor, and weather barriers. 
         [0033]    The wall panel assemblies  110 , such as provided above, can be secured to a building face in a number of ways. The following provides two example wall panel mounting assemblies that can be utilized to tie the wall panel assemblies  110  to a building face. 
         [0034]      FIGS. 1 and 3  illustrate an example of wall panels  110  mounted to the slab edges  250  of a building where the wall panel mounting assembly is configured as a J-bracket assembly  252 . For example, the J-bracket assembly  252  is designed for mounting insulated wall panel assemblies  110 , in a unitized configuration, to a slab edge  300  and to span the wall panel assemblies  110  floor-to-floor without requiring any additional support framing. 
         [0035]    The J-bracket assembly  252  includes a slab edge “J” hanger bar  254  that is attached to fasteners such as threaded rods  256  which are embedded in the concrete slab  250 . The J-bracket assembly  252  also includes a jamb plate  258 , a sliding clip  260 , and an adjustment bolt  262  that are configures to support the load of the wall panels  110  and transfer the loads to the building structure  300 . The J-bracket assembly  252  is disposed at the top and bottom slab edges  300  of the building structure and combines with the strength the wall panel assemblies  110  so that they act compositely to support all imposed loads. 
         [0036]      FIG. 5  illustrates a set of wall panels  110  mounted to an existing wall. While the wall panels  110  can be mounted in a variety of ways, in one arrangement, the wall panels mount utilizing a set of Z-bracket assemblies. In one arrangement, the Z-bracket assembly  270  includes a first or bottom z-shaped extrusion  272  and a second or top z-shaped extrusion  274  that interact to secure each wall panel  110 - 1 ,  110 - 2  to a corresponding wall  280 - 1 ,  280 - 2 . 
         [0037]    In one arrangement, the top extrusion  274  includes adjustable setting fasteners  276 , such as bolts, that secure the top extrusion  274  to the corresponding wall panel  110 - 1 . The fasteners  276  are configured to support the weight of the panel assemblies  110  and allow for vertical adjustment of the unitized panel sections  110  during installation. The bottom extrusion  272  is configured to be secured to a wall structure  280  of a building, such as via fasteners  277 . 
         [0038]    The top extrusion  274  works in conjunction with the bottom extrusion  274  to transfer the weight of the panel  110  to the building structure  280 . For example, a portion of the top extrusion  274  is disposed within a gap defined between the bottom extrusion  272  and the wall  280  while a portion of the bottom extrusion  272  is disposed within a gap defined between the top extrusion  274  and the wall panel assembly  110 . Accordingly, the top and bottom extrusions  274 ,  272  interlock together to transfer horizontal loads to the building structure  280  while allow for vertical building movements. 
         [0039]    While there is shown and described herein certain specific structure embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.