Thermal clip system and apparatus for a building wall assembly

A thermal clip system suitable for use with a wall assembly. The clip comprises a base section and an arm section. According to an embodiment, the clip is formed a unitary piece from extruded aluminum. The base section is configured with mounting holes for receiving fasteners to secure the clip respective studs in a wall. The arm section includes a surface for fastening a girt member, wherein the girt member is configured to secure one or more exterior cladding panels. The base section may include a recessed cavity for receiving an insulating material to form a thermal break between the clip and the stud wall. The arm section may include a recessed slot for receiving an insulating material to form a thermal break between the clip and the girt member.

FIELD OF THE INVENTION

The present invention relates to wall assemblies and more particularly, to a thermal clip system and apparatus suitable for use with wall assemblies or modules having an outer cladding.

BACKGROUND OF THE INVENTION

In the building arts, insulation of exterior walls is an important design consideration, particularly in northern or extreme climates.

One building system found in the art is an exterior cladding system comprising a framework structure coupled to the exterior wall with exterior cladding panels connected to the framework. The exterior cladding panels can be engineered and fabricated to provide various aesthetic characteristics in addition to useful thermal and weather resistant properties. For example, the cladding panels and frame structure can comprise a rear ventilated rain-screen (RVRS) exterior wall structure.

A shortcoming with these types of systems is the connection between the exterior cladding framework structure and the exterior wall provides a thermal path for the escape of thermal energy, e.g. heat in winter and cooled air in summer. In addition, building code requirements are increasingly specifying improved thermal characteristics. For instance, the current industry standard for attachment of cladding type systems is inefficient in terms of effective R-Value. Compared to the nominal amount of insulation used in the assembly, the thermal resistance of the continuous vertical girt or continuous horizontal girt is typically only 40-60% effective. Therefore, typical traditional systems do not meet the prescriptive requirements of the national building code.

Accordingly, there remains a need for improvements in the art.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to a thermal clip system, configuration and method suitable for use with a wall assembly or a modular wall or cladding system.

According to one embodiment, the present invention comprises a clip for a wall system, the wall system comprises one or more stud members configured for a wall and one or more girt members configured for connecting one or more external cladding panels, the clip comprises: a base section having a mounting surface and being configured with one or more openings for receiving one or more respective fasteners for securing the base section to the one of the respective stud members; an arm section extending generally perpendicularly from the base section, and the arm section having a surface for supporting and securing a section of one of the girt members; the base member having a recessed cavity formed in a section of the mounting surface, and the recessed cavity being configured for receiving an insulating material so as to provide a thermal break between the base member and the internal wall.

According to another embodiment, the present invention comprises an exterior wall assembly for a building comprising: a backing wall comprising a plurality of stud members arranged in a spaced relationship; a plurality of clip members fastened to respective stud members in the backing wall; a plurality of horizontal girt members, each of the horizontal girt members having a mounting face; a plurality of vertical girt members, each of the vertical girt members being configured for fastening to the mounting face of the respective horizontal girt members to form a frame structure, and one or more of the vertical girt members having a mounting surface for attaching one or more exterior cladding panels; and each of the plurality of clip members comprising, a base section having a mounting surface and being configured with one or more openings for receiving one or more respective fasteners for securing the base section to one of the respective stud members; an arm section extending generally perpendicularly from the base section, and the arm section having a surface for supporting and securing a section of one of the horizontal girt members; the base member having a recessed cavity formed in a section of the mounting surface, and the recessed cavity being configured for receiving an insulating material so as to provide a thermal break between the base member and the internal wall.

According to another embodiment, the present invention comprises a clip for a wall system, the wall system comprising one or more stud members configured for a wall and one or more girt members configured for connecting one or more external cladding panels, the clip comprising: a base section having a mounting surface and being configured with one or more openings for receiving one or more respective fasteners for securing the base section to one of the respective stud members; an arm section extending generally perpendicularly from the base section, and the arm section having a surface for supporting and securing a section of one of the girt members; and the surface of the arm section includes a recessed slot configured for receiving an insulating material so as to provide a thermal break between the girt member and the arm section.

Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of embodiments of the invention in conjunction with the accompanying figures.

Like reference numerals indicate like or corresponding elements or components in the drawings.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

Reference is made toFIGS. 1 and 2(a),2(b), which show in diagrammatic form an exemplary wall assembly and configuration comprising a thermal clip assembly or configuration according to an embodiment of the present invention and indicated generally by reference100. The wall assembly100comprises a wall102(e.g. an internal stud back-up wall) comprising a wall frame formed with studs110(e.g. steel studs) and a sheathing layer112(e.g. gypsum/cellulose exterior sheathing panels), and an exterior cladding system indicated generally by reference104. The exterior cladding system utilizes an arrangement of girts comprising horizontal girt or sub-girt members (e.g. “zee-gifts”)120and vertical girt members122. InFIG. 1, the vertical girt members122are indicated individually by references122a,122b,122c,122d. . . . The vertical girt members122are fastened to the horizontal girt members120to form a frame structure for attaching and supporting external cladding sheets or panels124, for example, as shown inFIGS. 3(a) and3(b). The horizontal girt members120are attached or affixed to the wall102by respective thermal clips130indicated individually by references130a,130b,130c,130d. . . as shown inFIG. 1. As will be described in more detail below, each thermal clip130is affixed to a respective stud110using suitable fasteners or connectors111(for example, “self-drilling” hex washer head screws). Similarly, the horizontal girt member120is connected to the respective thermal clip members130using suitable fasteners113(for example, “self-tapping” hex head screws), and the vertical girt member122is connected to the respective horizontal girt members120using suitable fasteners115(for example, “self-drilling” hex washer head screws).

Reference is next made toFIGS. 3(a),3(b) and4(a),4(b), which show the thermal clip130according to an embodiment in greater detail. The thermal clip130comprises a base section131and an arm section132. The arm section132is generally perpendicular to the base section131and provides a surface for supporting and/or fastening the horizontal girt (i.e. “zee-girt”) for example as depicted inFIG. 3(a). According to an exemplary implementation, the thermal clip130is formed or fabricated from extruded aluminum as a unitary piece. The base member131is configured to attach to the wall102, and according to an embodiment comprises holes136(e.g. punched or drilled) for receiving suitable fasteners137(e.g. self-drilling hex head screws) that penetrate through the sheathing layer112and screw directly into the steel stud110(FIG. 3(b)) to securely fasten the thermal clip130to the wall102. According to another aspect, the wall102can include a vapour barrier layer indicated generally by reference113(FIG. 3(a)), which is installed in a manner as will be readily understood by one skilled in the art. As also shown inFIGS. 3(a) and4(a), the base section131may also include feet or extended end sections indicated generally by reference133. The extended end sections133are formed in the base section131and facilitate achieving a “flush” connection or distributed load surface between the base section131of the thermal clip130and the exterior surface of the wall102.

According to another aspect, the thermal clip130comprises a recessed slot or cavity that is formed in the base section131, e.g. in the surface that mounts against the wall, and indicated generally by reference138as shown inFIGS. 3(a) and4(a). The recessed slot138is configured to receive a high efficient insulating material indicated generally by reference139, which provides a thermal break between the exterior and interior surfaces of the wall102. According to an exemplary implementation, the thermal break insulating layer139comprises Thermablok™ high performance silica aerogel insulation with a self-adhesive backing layer for securing to the inside surface of the recessed cavity138. It will however be appreciated that other suitable thermal insulating materials may be used to provide a thermal break.

As shown inFIGS. 3(a) and4(a), the arm section132is formed to provide a support surface for supporting and fastening the horizontal girts120(i.e. sub-girts). According to one aspect, the arm section132has a sufficient thickness to support the distributed weight of the horizontal and vertical girt members120,122and the external cladding panels124(including the bending moment load). According to an exemplary implementation, the horizontal girt member120is connected directly to the arm section132of the thermal clip130using a suitable fastener indicated generally by reference141, such as self-tapping hex head screws, which are screwed directly into the body of the arm section132. According to another aspect, the arm section132is configured to allow the horizontal girt120to be positioned (and fastened) in more than location, i.e. offset or extending outwards from the base section131, as indicated by references142a,142band142cinFIG. 3(a). According to an exemplary implementation, the arm section132is configured to provide a span in the range of approximately 90 mm. According to another aspect, the size or span of the thermal clip130is determined by the thickness of the required or specified insulation layer127(for example as depicted inFIG. 3(a)).

As shown inFIGS. 3(a) and4(a), the thermal clip130may include another thermal break section according to an embodiment of the invention. As shown, the arm section132includes a recessed slot or cavity indicated generally by reference135and configured for receiving a thermal insulating material indicated generally by reference139. As shown inFIG. 3(a), the thermal insulating layer139is effectively “sandwiched” between the horizontal sub-girt member120and the arm section132of the thermal clip130. Since both of these components may be formed of a metallic material, the thermal insulating layer139provides a thermal break, i.e. thermal barrier. According to an exemplary implementation, the thermal insulating layer139comprises cork-neoprene material, for example, High-Tensile Cork-Neoprene Tape from Jacobs & Thompson.

Referring toFIGS. 3(a) and3(b), the horizontal girt120includes a front flange or face121, which is configured to provide a mounting surface for securing the respective vertical girt member122. According to an exemplary implementation, the vertical girt member122is secured to the horizontal girt member120utilizing self-drilling type hex head screws. As also shown inFIGS. 3(a) and3(b), the external cladding sheets or panels124are secured to respective sections of the vertical girt members122using suitable fasteners125, such as, stainless steel rivets with a separate stainless steel filler cylinder. According to an exemplary implementation, the external cladding panels124and the horizontal girts120and the vertical girts122comprise a rear ventilated rain screen (RVRS) structure. These and other particular implementation and assembly details will be within the understanding of one skilled in the art. A void indicated generally by reference126is formed between the wall102and the external cladding layer124as depicted inFIGS. 3(a) and3(b). In known manner, the void126serves to provide a thermal break (and ventilation path or space). According to another aspect, the thermal properties of the void126may be improved by installing an insulation layer indicated generally by reference127, for example, Roxulplus™ semi-rigid mineral wool insulation.

According to another embodiment, the wall102comprises a slab structure and the thermal clips130are configured to be fastened to respective sections of the slabs, in addition to the studs110.

Reference is next made toFIGS. 5(a) and5(b), which show a thermal clip according to another embodiment of the invention and indicated generally by reference530. The thermal clip530comprises a base section531and an arm section532. The base section531is configured with openings536for receiving fasteners and securing the thermal clip to studs110in the wall102, for example, as described above with reference toFIG. 3(a). The base section530may also include extended sections or feet indicated generally by reference533to provide a larger or increased mounting surface for securing the base section531against the wall102and/or distributing the structural load. As described above with reference toFIGS. 3(a) and3(b), the arm section532is generally perpendicular to the base section531and provides a surface for supporting and/or fastening the horizontal girt120(i.e. zee-girt). According to this embodiment, the longitudinal dimension of the arm section532has been increased, for example, to approximately 115 mm, in order to provide a greater span between the exterior wall102(FIG. 3(a)) and the exterior cladding layer124(FIG. 3(a)). According to an exemplary implementation, the thermal clip530is formed from extruded aluminum as a unitary piece. With the increased span (i.e. length) of the arm section532the thickness and/or material composition is suitably modified to accommodate the increased structural loading (e.g. bending moment loading).

As shown inFIG. 5(a), the thermal clip530may be configured with a recessed slot or cavity538in the base section531and/or a recessed slot or cavity534in the arm section532. As described above for the thermal clip130, the recessed slots534,536are configured to receive or hold an insulating material535,539and provide a thermal break between the thermal clip530and the exterior wall102, and the horizontal sub-girt120(FIG. 3(a)) and the thermal clip530, respectively. According to another aspect, the recessed slot534includes a cross-rib540which effectively divides the slot534into two sections537aand537b. The cross-rib540provides support surface for supporting the horizontal sub-girt120when it is mounted away from the base section531, for example, in position142c(FIG. 3(a)). With this configuration, each of the slot sections537aand537bis configured to receive an insulating material or strip, for example, as described above.

Reference is next made toFIGS. 6(a) and6(b), which show a thermal clip according to another embodiment of the invention and indicated generally by reference630. As compared to the thermal clip130ofFIGS. 4(a),4(b) and the thermal clip ofFIGS. 5(a),5(b), the thermal clip630is configured to provide an even greater span, in range of approximately 140 mm. The thermal clip630comprises a base section631and an arm section632. The base section631is configured with openings636for receiving fasteners and securing the thermal clip to studs110in the wall102, for example, as described above with reference toFIG. 3(a). The base section630may also include extended sections or feet indicated generally by reference633to provide an increased mounting surface for securing the base section631against the wall102, and/or distributing the structural load. As described above with reference toFIGS. 3(a) and3(b), the arm section632is generally perpendicular to the base section631and provides a surface for supporting and/or fastening the horizontal girt120(i.e. zee-girt). According to this embodiment, the longitudinal dimension of the arm section632has been increased, for example, to provide a greater span between the exterior wall102(FIG. 3(a)) and the exterior cladding layer124(FIG. 3(a)). According to an exemplary implementation, the thermal clip630is formed from extruded aluminum as a unitary piece. With the increased span (i.e. length) of the arm section632the thickness and/or material composition is suitably modified to accommodate the increased structural loading (e.g. bending moment loading).

As shown inFIG. 6(a), the thermal clip630may be configured with a recessed slot or cavity638in the base section631and/or a recessed slot or cavity634in the arm section632. As described above for the thermal clip530, the recessed slots634,636are configured to receive or hold an insulating material and provide a thermal break between the thermal clip630and the exterior wall102, and/or the horizontal sub-girt120(FIG. 3(a)) and the thermal clip630, respectively. According to another aspect, the recessed slot634includes a cross-rib640which effectively divides the slot634into two sections637aand637b. The cross-rib640provides support surface for supporting the horizontal sub-girt120when it is mounted away from the base section631, for example, in position142c(FIG. 3(a)). With this configuration, each of slot sections637aand637bis configured to receive an insulating material or strip, for example, as described above.

It will be appreciated that while the embodiments of the clip were described as being fabricated from extruded aluminum, other materials and fabrication techniques, e.g. unitary and/or multi-component or welded configurations may be utilized.