Abstract:
An aluminum wall panel comprising a plate, a top flange extending from a top of the plate, a bottom flange extending from a bottom of the plate, a first side flange extending from a first side of the plate and a second side flange extending from a second side of the plate. The panel includes a first projection and a second projection extending from the top flange and defining a channel therebetween. The panel also includes a third resilient projection extending from the bottom flange. The third resilient projection presses against a matching projection of the second wall panel to rigidly connect the wall panel to the second wall panel when the wall panel and the second wall panel are fixed to a supporting framework. The first side flange and the second side flange taper upwards to allow the plate to be parallel with the second wall panel.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention relates to a building, and in particular to an exterior or interior wall of a building.  
           [0002]    Exterior walls of buildings protect the outside of the building from the elements and prevents rain and other precipitation from entering the building. The exterior walls of buildings also provide insulation from the temperatures of the outside air. Furthermore, exterior walls of a building can provide an aesthetically pleasing appearance.  
           [0003]    Heretofore, exterior walls of buildings have been designed using panels that are located about an exterior facing of the buildings and are typically sealed to the exterior facing and to each other using a sealant or gaskets. However, the sealant and gaskets can sometimes fail, thereby reducing the efficiency of the wall panels. Furthermore, adding the sealant and gaskets can be very time consuming, thereby adding expensive labor costs to the construction of the buildings. One attempt to a solution to the above problems is disclosed in U.S. Pat. No. 5,636,489 to Leverrier et al. The wall panels as disclosed by Leverrier et al. include a groove along the top of the panels for accepting a flange extending from the bottom of a panel positioned thereabove. The wall panels are connected to the exterior facing by placing fasteners only through the top of the wall panels. However, the wall panels as disclosed by Leverrier et al. are made of polyester, which sometimes does not have a long lifespan when exposed to harsh environments. Additionally, the wall panels as disclosed by Leverrier et al. can sometimes be loosely connected to adjacent wall panels at the bottom of the wall panels because the movement of the flange extending from the bottom of the wall panel in its associated groove. Furthermore, since a portion of the wall panels extend over a portion of the wall panels placed therebelow, the wall panels are sometimes not all located on a single plane, thereby providing an aesthetically displeasing appearance.  
           [0004]    Accordingly, wall panels solving the aforementioned disadvantages and having the aforementioned advantages is desired.  
         SUMMARY OF THE INVENTION  
         [0005]    The wall panels of the present invention can easily be connected to a supporting structure without sealants or gaskets. In a first aspect of the present invention, the wall panels include a resilient projection pressing against a matching projection of a second wall panel to rigidly connect the wall panel to the second wall panel when the wall panel and the second wall panel are fixed to a supporting framework. In a second aspect of the present invention, wall panels include a pair of side flanges that taper upward to allow each of the wall panels to be parallel with other wall panels. In a third aspect of the present invention, the wall panel is made from one of aluminum, stainless steel, zinc or copper.  
           [0006]    These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    [0007]FIG. 1 is a perspective view of a wall of the present invention.  
         [0008]    [0008]FIG. 2 is a front view of a wall panel of the present invention.  
         [0009]    [0009]FIG. 2A is a left side view of the wall panel of the present invention.  
         [0010]    [0010]FIG. 2B is a right side view of the wall panel of the present invention.  
         [0011]    [0011]FIG. 3 is a cross-sectional view of the wall panel of the present invention taken along the line III-III of FIG. 2.  
         [0012]    [0012]FIG. 4 is a cross-sectional view of the wall panel of the present invention taken along the line IV-IV of FIG. 2.  
         [0013]    [0013]FIG. 5 is a cross-sectional view of the bottom of the wall of the present invention.  
         [0014]    [0014]FIG. 6 is a cross-sectional view of the wall of the present invention taken along the line VI-VI of FIG. 1.  
         [0015]    [0015]FIG. 7 is a cross-sectional view of the wall of the present invention taken along the line VII-VII of FIG. 1.  
         [0016]    [0016]FIG. 8 is a cross-sectional view of an inside corner of the wall of the present invention.  
         [0017]    [0017]FIG. 9 is a cross-sectional view of an outside corner of the wall of the present invention.  
         [0018]    [0018]FIG. 10 is a cross-sectional view of a top of the wall of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0019]    For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as orientated in FIG. 1. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.  
         [0020]    The reference number  10  (FIG. 1) generally designates a wall embodying the present invention. In the illustrated example, the wall  10  includes a plurality of identical wall panels  12 . The wall panels  12  are preferably located on the exterior or interior of a building for protecting the building against the elements and for providing the exterior of the building with a decorative design. Each wall panel  12  is preferably made from a sheet of folded is made from one of aluminum, stainless steel, zinc or copper to form an integral panel  12 .  
         [0021]    The illustrated wall panels  12  (FIGS.  2 - 4 ) each include a substantially rectangular plate  14 , a top flange  16 , a first projection  18  and a second projection  20  extending from the top flange  16 , a bottom flange  22  and a third resilient projection  24  extending from the bottom flange  22 . The top flange  16  and the bottom flange  20  are used to connect a pair of vertically adjacent wall panels  12 . The top flange  16 , first projection  18  and the second projection  20  extend rearwardly from a top  26  of the plate  14  and are preferably an integral section  28  folded several times to form the finished configuration for the top flange  16 , first projection  18  and the second projection  20 . The integral section  28  includes a first top horizontal sheet  30  extending rearward from the top  26  of the plate  14 . The integral section  28  also includes a first top vertical sheet  32  extending upward from an end  34  of the first top horizontal sheet  30 , with the first top vertical sheet  32  being folded over at a top fold point  36  to form a second top vertical sheet  38  overlapping the first top vertical sheet  32 . The integral section  28  further includes a second top horizontal sheet  40  extending forward from an end of the second top vertical sheet  38  and overlapping the first top horizontal sheet  30 . Finally, a third top vertical sheet  42  extends upward from an end of the second top horizontal sheet  40 . The third top vertical sheet  42  forms the first projection  18  and the first top vertical sheet  32  and the second top vertical sheet  38  form a second projection  20 . A channel  48  is thereby formed between the first projection  18  and the second projection  20 . The bottom flange  22  extends rearwardly from a bottom  50  of the plate  14  and the third resilient flange  24  extends downwardly and forwardly from the rear edge of flange  22 , at an acute angle to the flange  22 . Like the top flange  16 , flanges  22  and  24  are preferably formed from an integral section  52  folded to form the finished configuration for the bottom flange  20  and the third resilient flange  24 . The integral section  52  of the wall panel  12  includes a bottom horizontal sheet  48  extending rearwardly from the bottom  50  of the plate  14  and the third resilient projection  24  extending forwardly and downwardly from an end  54  of the bottom horizontal sheet  48 . As described in more detail below, the third resilient projection  24  is configured to be placed within the channel  48  of a second wall panel  12  positioned below the wall panel  12  for connecting the pair of vertically adjacent wall panels  12 .  
         [0022]    In the illustrated example, the wall panel  12  also includes a first side flange  56  extending rearwardly from a first side  58  of the plate  14  and a second side flange  60  extending rearwardly from a second side  62  of the plate  14 . The first side flange  56  includes a first side first sheet  64  extending rearwardly from the first side  58  of the plate  14 , a first side second sheet  66  extending outwardly from an end of the first side first sheet  64  and a first side third sheet  68  extending forwardly from an end of the first side second sheet  66 . A slot  70  is thereby formed between the first side first sheet  64  and the first side third sheet  68 . The second side flange  60  includes a second side first sheet  72  extending rearwardly from the second side  62  of the plate  14 , a second side second sheet  74  extending outwardly from an end of the second side first sheet  72  and a second side third sheet  76  extending rearwardly from an end of the second side second sheet  74 . As described in more detail below, the second side third sheet  76  is configured to be placed within the slot  70  of a third wall panel  12  positioned adjacent the second side  62  the wall panel  12  for connecting the pair of horizontally adjacent wall panels  12 .  
         [0023]    The illustrated wall panels  12  are used to form the wall  10  by first providing a supporting framework  78  on the building (FIG. 1). The supporting framework  78  is any framework that can accept fasteners therein and can support the wall panels  12 . In FIG. 1, the supporting framework  78  is shown as being a metal panel substrate  80  configured to be attached to metal studs  82  of a building and a plurality of horizontally and vertically aligned U-shaped beams  84  connected to the metal panel substrate  80 . Although the metal panel substrate  80  and the U-shaped beams  84  are shown as forming the supporting framework  78 , the supporting framework can be any support that will support the wall panels  12 . For example, the supporting framework  78  could be concrete, wood or any other configured framework.  
         [0024]    Before the wall panels  12  are connected to the supporting framework  78 , a bottom retaining member  86  is preferably located along the bottom of the supporting framework  78 . The illustrated bottom retaining member  86  (FIGS. 1 and 5) is a U-shaped sill having a first leg  88 , a second leg  90  and a cross leg  92 . The first leg  88 , the second leg  90  and the cross leg  92  define a recess  94  for receiving the bottom flange  22 , the third resilient projection  24  and a bottom portion of the plate  14  of the panel  12 . The bottom retaining member  86  is connected to the supporting framework  78  by first connecting a weather drip  96  along a bottom of the supporting framework  78  with a first fastener  98 . The second leg  90  of the bottom retaining member  86  is thereafter also connected to the bottom of the supporting framework  78  with a second fastener  100 . The bottom of the panel  12  is then placed within the recess  94  of the bottom retaining member  86 , thereby retaining and covering the bottom flange  22 , the third resilient projection  24  and a bottom portion of the plate  14  of the panel  12 . Although the bottom retaining member  86  is described as retaining the bottom of the panel  12 , it is contemplated that other means of retaining the bottom of the panel  12  can be used.  
         [0025]    The wall panels  12  are connected to the structural framework  78  to form the wall  10  (FIG. 1) by first placing the bottom of the bottommost and leftmost wall panel  12 A into the bottom retaining member  86 . Third fasteners  102  (see FIG. 6) are then placed through apertures  104  in the first top vertical sheet  32  and the second top vertical sheet  38  of the second projection  20  of the panel  12  and into the U-shaped beams  84  of the structural framework  78 . The remaining wall panels  12 A′ of the bottom row of the wall  10  are then placed into position one-by-one and moving towards the right by inserting the bottom of the wall panel  12 A′ into the bottom retaining member  86  as described above and by placing the second side third sheet  76  of the second side flange  60  into the slot  70  of the first side flange  56  of the wall panel  12 A′ adjacent on the left (see FIG. 7). Third fasteners  102  are placed through the apertures  104  in each of the walls panels  12 A′ to connect the wall panels  12 A′ to the supporting framework  78 .  
         [0026]    After the bottom row of wall panels  12 A′ are connected to the supporting framework  78 , a second bottommost row of wall panels  12 B are connected to the supporting framework  78 . As seen in FIG. 6, the leftmost wall panel  12 B is connected to the wall panel  12 A in the bottom row of wall panels  12 A by inserting the third resilient flange  24  of the leftmost wall panel  12 B into the channel  48  of the wall panel  12 A. The wall panel  12 B is moved into position by first inserting the third resilient flange  24  into the channel  48  with a top of the wall panel  12 B away from the supporting framework  78 . The top of the wall panel  12 B is then rotated towards the supporting framework  78  along arrow  79 . In the illustrated embodiment, the third resilient flange  24  has a horizontal length greater than the distance between the first projection  18  and the second projection  20 . Therefore, a front edge  106  of the third resilient flange  24  will press against the inside face  108  of the first projection  18  as the wall panel  12 B is rotated into position. Additionally, the end  54  of the bottom horizontal sheet  48  of the bottom flange  22  will press against the inside face  110  of the second projection  20 . As the wall panel  12 B is rotated into position, the third resilient flange  24  will create a moment on the wall panel  12 B forcing the top of the wall panel  12 B away from the supporting framework  78 . Consequently, when third fasteners  102  are placed through the apertures  104  in the wall panel  12 B, the top of the wall panel  12 B will be rigidly connected to the supporting framework  78  and the bottom of the wall panel  12 B will be pressed against the inside face  108  of the first projection of the wall panel  12 A, thereby maintaining the wall panel  12 B in position.  
         [0027]    The remaining wall panels  12 B′ in the second row of wall panels  12 B′ are then placed into position one-by-one and moving towards the right by inserting the third resilient flange  24  of the wall panel  12 B′ into the channel  48  of the wall panel  12 A′ as described above and by placing the second side third sheet  76  of the second side flange  60  into the slot  70  of the first side flange  56  of the wall panel  12 A′ adjacent on the left. Third fasteners  102  are placed through the apertures  104  in each of the wall panels  12 B′ to connect the wall panels  12 B′ to the supporting framework  78 . Each successive row of wall panels  12  are thereafter placed into position by moving upward to form each vertical row and by moving to the right to position each wall panel  12  into position in the vertical row.  
         [0028]    In the illustrated example, the bottom portion of each of the wall panels  12  is positioned further away from the supporting framework  78  than the top portion of the wall panels  12  because the bottom portion of the wall panels  12  overlaps a portion of the walls panels  12  (or the bottom retaining member  86 ). Therefore, as seen in FIGS. 2A and 2B, a top width  200  of the first side flange  56  and the second side flange  60  adjacent the top flange  16  is larger than a bottom width  202  of the first side flange  56  and the second side flange  60  adjacent the bottom flange  22 . The first side flange  56  and the second side flange  60  preferably taper from the width of the top flange  16  to a width equal to the width of the top flange  16  minus the width of the second projection  20 . Therefore, the plate  14  of each wall panel  12  will be vertically positioned and aligned with the other wall panels  12  of the wall  10  when the wall panels  12  are placed into position.  
         [0029]    In addition to the bottom retaining member  86 , the illustrated wall  10  can include an inside corner retaining member  120  (FIG. 8) and an outside corner retaining member  121  (FIG. 9) for retaining sides of the wall panels  12  at corners of buildings and a top retaining member  122  (FIG. 10) for covering the top of the wall panels  12  at the top of the walls  10 . The inside corner retaining member  120  includes a pair of substantially U-shaped members  124  forming a first corner recess  126  and a second recess  128 . In the illustrated example, the first corner recess  126  and the second corner recess  128  are perpendicular. However, the first corner recess  126  and the second corner recess  128  can be at any angle, depending on the angle of the corner. The substantially U-shaped members  124  of the inside corner retaining member  120  includes an outwardly facing leg  140  and an inwardly facing leg  142 . The inwardly facing leg  142  is longer than the outwardly facing leg  140  and is adjacent the supporting framework  78 . The substantially U-shaped members  124  of the inside corner retaining member  120  are connected to each other at a junction point  144  between the outwardly facing leg  140  and a cross leg  146  between the inwardly facing leg  140  and the outwardly facing leg  142 . The inside corner retaining member  120  is connected to the supporting framework  78  by inserting fourth fasteners  130  through openings in the inwardly facing legs  140  of each of the substantially U-shaped members  124 . The outside corner retaining member  121  also includes a pair of substantially U-shaped members  124  forming a first corner recess  126  and a second recess  128 . In the illustrated example, the first corner recess  126  and the second corner recess  128  are perpendicular. However, the first corner recess  126  and the second corner recess  128  can be at any angle, depending on the angle of the corner. The outside corner retaining member  121  includes a pair of substantially U-shaped members  125  forming a first corner recess  127  and a second recess  129 . The inwardly facing leg  150  is longer than the outwardly facing leg  150  and is adjacent the supporting framework  78 . The substantially U-shaped members  125  of the outside corner retaining member  121  include a single cross leg  156  connected to each inwardly facing leg  150  and outwardly facing leg  152  of both of the substantially U-shaped members  125 . The outside corner retaining member  121  is connected to the supporting framework  78  by inserting fourth fasteners  130  through openings in the inwardly facing legs  150  of each of the substantially U-shaped members  125 . In the illustrated example, the first corner recess  127  and the second corner recess  129  are perpendicular. However, the first corner recess  127  and the second corner recess  129  can be at any angle, depending on the angle of the corner.  
         [0030]    The illustrated wall  10  can also include a top retaining member  122  (FIG. 10) for covering the top of the wall panels  12  at the top of the walls  10 . The top retaining member  122  is similar to the bottom retaining member  86  and includes a substantially U-shaped member  130  defining a top recess  132 . The top retaining member  122  includes a first leg  134  connected to a rear of the structural framework  78  and a second leg  136  that covers the top of the wall panel  12 , with the top of the wall panel  12  being located within the top recess  132 . It is further contemplated that other retaining members can be used to retain the top, the bottom or the sides of the wall panels.  
         [0031]    The wall  10  therefore includes wall panels that overlap and interlock together to form a pressure equalized rain screen for the building. The wall panels  12  can be installed in any weather without special equipment or temperature requirements and are made from long lasting aluminum. With only  3  fasteners  102  per wall panel  12 , the wall panels  12  can be installed quickly. Furthermore, with no joint sealants or gaskets all of the joints of the wall panels  12  remain dry.  
         [0032]    It will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. For example, although the wall  10  is easily constructed without sealants or gaskets, it is contemplated that sealants and gaskets can be used during the building of wall  10 . Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.