Attachment system for panel or facade

Panels (20A, 20B) are attached to extrusions (66A, 66B) by fasteners 90. Clips (70) are attached to a structure (50) by fasteners (35). The extrusions and the clips engage in a manner which allows the panels to move in any direction, as needed, without the panel detaching from the structure and falling. The extrusions also provide for the use of optional reveal strips (87). An extrusion has a restraining area (86), a reveal strip stop area (58), and a T-slot (65). A clip has a T-channel (74), a tensioning stop arm (69), and a secondary reinforcing arm (80). The panels can be installed in rows, in columns, or diagonally, as desired.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates generally attachment systems for wall panels or facades and, more particularly, to an attachment system which provides for four-way movement of the panel or facade.

(2) Description of the Related Art

Existing attachment systems do not provide for four-way movement of the panels, require extensive on-site preparation or modification, and can disengage from the panel, allowing the panel to fall out, if the panel moves beyond a very limited amount, is improperly installed, or contracts beyond a very limited amount.

BRIEF SUMMARY OF THE INVENTION

One embodiment of the present invention provides an apparatus for securing a first panel and a second panel to a structure, each panel having a main portion, a lip, and a hole in the lip. The apparatus includes a clip and first and second extrusions. The clip includes a clip base having a first area and a second area, a generally “T”-shaped track extending from the first area, and a generally “L”-shaped stop. The “L”-shaped stop has a first base extending from the second area at approximately 90 degrees and an arm extending from the distal end of the first base at approximately 90 degrees, the arm generally extending parallel to the clip base and away from the first area. The clip base has a hole between the “T”-shaped track and the “L”-shaped stop and adapted to accommodate a fastener to secure the clip to the structure.

An extrusion includes a generally “U”-shaped base, a first leg, and first and second generally “L”-shaped extensions. The “U”-shaped base has a first arm and a second arm, and the second arm has an end and a base. The “U”-shaped base is adapted to receive an “L”-shaped stop of the clip. The first leg extends at approximately 90 degrees from the first arm of the “U”-shaped base and has a hole therein to accommodate a fastener to secure the extrusion to a panel. The first extrusion is secured to the first panel and the second extrusion is secured to the second panel. A generally “L”-shaped extension extends at approximately 90 degrees from the second arm of the “U”-shaped base, the first extension extends from the end of the second arm, the second extension extends from the base of the second arm. The second arm, the first extension and the second extension form a generally “T”-shaped opening adapted to receive the “T”-shaped track. The “U”-shaped base of one extrusion receives the “L”-shaped stop and the “T”-shaped opening of the other extrusion receives the “T”-shaped track.

In another embodiment, the clip further comprises a generally “L”-shaped extension having a base and an arm and extending from the clip base, the “T”-shaped track being between the “L”-shaped extension and the hole, the base of the “L”-shaped extension extending at approximately 90 degrees from the clip base, the arm extending at approximately 90 degrees from the distal end of the base of the “L”-shaped extension, and the arm generally extending parallel to the clip base and toward the second area.

In another embodiment, at least one extrusion further comprises a third arm extending at approximately 90 degrees from the base of the “U”-shaped base and forming a first receptacle area with respect to the first arm of the “U”-shaped base and a second receptacle area with respect to the second arm of the “U”-shaped base, the first receptacle adapted to receive a reveal strip, the second receptacle adapted to receive the “L”-shaped stop of the clip.

In another embodiment, the third arm has a knob on the end.

In another embodiment, the “L”-shaped stop has a knob on the distal end.

Yet another embodiment of the present invention provides an apparatus to secure a panel having an extrusion to a structure. The apparatus includes a clip base, a generally “T”-shaped track, and a generally “L”-shaped stop. The clip base has a first area and a second area. The generally “T”-shaped track extends from the first area and is adapted to engage the extrusion. The generally “L”-shaped stop is adapted to engage the extrusion, and has a first base extending from the second area at approximately 90 degrees and an arm extending from the distal end of the first base at approximately 90 degrees. The arm generally extends parallel to the clip base and away from the first area. The clip base has a hole between the “T”-shaped track and the “L”-shaped stop and is adapted to accommodate a fastener to secure the clip to a structure.

In another embodiment, the apparatus also has a generally “L”-shaped extension having a base and an arm and extending from the clip base, where the “T”-shaped track being between the “L”-shaped extension and the hole. The base of the “L”-shaped extension extends at approximately 90 degrees from the clip base, the arm extends at approximately 90 degrees from the distal end of the base of the “L”-shaped extension, the arm generally extends parallel to the clip base and toward the second area.

In another embodiment the “L”-shaped stop has a knob on the distal end.

In still another embodiment the apparatus has a generally “U”-shaped base, a first leg, and first and second generally “L”-shaped extensions. The generally “U”-shaped base has a first arm and a second arm, the second arm has an end and a base, and the “U”-shaped base is adapted to engage a clip. In another embodiment the first leg extends at approximately 90 degrees from the first arm of the “U”-shaped base and has a hole therein to accommodate a fastener to secure the apparatus to the panel. A generally “L”-shaped extensions extends at approximately 90 degrees from the second arm of the “U”-shaped base, the first extension extends from the end of the second arm, the second extension extending from the base of the second arm, and the second arm, the first extension and the second extension form a generally “T”-shaped opening adapted to engage the clip.

In another embodiment, there is a third arm extending at approximately 90 degrees from the base of the “U”-shaped base and forming a first receptacle area with respect to the first arm of the “U”-shaped base and a second receptacle area with respect to the second arm of the “U”-shaped base, the first receptacle is adapted to receive a reveal strip and the second receptacle is adapted to engage the clip.

In another embodiment, the third arm has a knob on the end.

Other objects, features, and advantages of the present invention will become apparent upon reading the following description of the preferred embodiment, when taken in conjunction with the drawings and the claims.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1is an illustration of an exemplary embodiment of the present invention in an exemplary environment10.FIG. 1depicts panels or façades20A,20B, each having a respective route and return leg or lip21, a pair of female mounting extrusions66A,66B, panel fasteners90for securing the panels20to their respective extrusions66, male attachment clip70, a plastic shim30, a vapor barrier40, a sound proofing and/or insulating barrier material88, such as gypsum board, a structural substrate89, and a fastener35, such as a TEK fastener, for securing the clip70to structural substrate89though the shim30and the barriers40and88. For convenience, barriers40and88, and the structural substrate89are collectively sometimes referred to herein as structure50. It will be appreciated that components40and88are for wind, rain, water, vibration and/or thermal considerations and are not required simply in order to secure a panel to the structure, but may be required for the considerations above and/or compliance with building codes and regulations. The components40and88are therefore not required for a exposed sealant system, but are often required and/or used with a dry seal system.

Also shown are an optional reveal strip87, an optional backing rod85, and an optional weather strip or sealant95. These components are used to prevent or minimize the amount of water which may be driven between the panel20and the structure50. Typically, either optional strip87will be used, e.g., a “dry seal” system, or optional rod85and strip95will be used, e.g., a “wet seal” system. If desired, however, components85,87and95may all be used so prevent or minimize the amount of such water.

The extrusions66and the clip70provide for fast, convenient, durable, and reliable attachment of the panel20to the surface89. Although the term “extrusion” is used herein for component66, it should be appreciated that the term “extrusion” is a common term in the industry for a component which is manufactured by extrusion. Therefore, as the preferred method of manufacture of component66is by extrusion, that term, extrusion, is used herein for convenience. It should be understood, however, that the use of the term extrusion is not intended to limit component66to manufacture by extrusion. Rather, it is intended that component66may be manufactured by any convenient method.

In one embodiment the apparatus includes a clip70and first and second extrusions66. The clip includes a clip base53having a first area53A and a second area53B, a generally “T”-shaped track74extending from the first area, and a generally “L”-shaped stop69. The clip base has a hole between the “T”-shaped track and the “L”-shaped stop adapted to accommodate a fastener. Consider first the construction of a male clip70. Components71,72and73of the clip70form a tensioning stop arm69. The end73of the arm72may be a bulb or other protrusion, or may be a bend in the arm72. This aids in guiding and inserting the arm69into the restraining area or pocket86of an extrusion66. Alternatively, the end73may be the same as the arm72, but the arm72may be bent at a slight angle to aid in insertion. Components75,76and77form a T-channel74. Optional components78and79form a secondary reinforcement mechanism80for the T-channel74.

Consider now the construction of the female extrusions66A,66B. Components61,62,63and64form a T-slot65for engagement with the T-channel74. The interior wall56, the reveal strip stop and corner reinforcement57, the base67, and the arm59form a reveal strip receptacle58for accepting and securing an optional reveal strip87. The arm59preferably has a knob or bulb or other protrusion60on the end so that the reveal strip87is held tightly against the interior wall56. The stop57limits the insertion of the reveal strip87into the receptacle58that the both ends of the reveal strip87are held by the extrusions66. Reveal strip stop and corner reinforcement57functions both as a reveal stop and to provide corner reinforcement. Arm59, end60, base67, and head62function to form a stop, restraining area, or pocket86for the tensioning stop arm69or a retainer bar103. The interior wall56, head62, and base67collectively form a U-shaped base.

A panel20is secured to an attachment leg54of an extrusion66by a fastener90. An optional panel stress relief51provides a stress relief for the panel20for positive pressure situations, that is, the wind is tending to force the panels20into the structure to which they are attached. Components52and55provide for optional corner reinforcement at the intersections of panel stress relief51and attachment leg54, and attachment leg54and interior wall56, respectively.

Shim30and barriers40and88are as specified by the drawing plans and/or code requirements.

From an inspection ofFIG. 1it will be seen that the male clip70is secured to the structural surface89by the fastener35. If there is positive pressure on the panels20A and20B, the panels20A,20B will exert force on the extrusions66A,66B, respectively, by their respective fasteners90and/or panel stress reliefs51. The force from the panels20A,20B will be applied to the clip70by the T-slot legs61and64of the respective extrusions66A,66B. In the case of panel20B and extrusion66B, the force from the panel20B, to a lesser degree, may also be applied to the tensioning stop arm69of the clip70by the arm59. The clip70then presses against the shim30and the structure50.

If there is negative pressure on the panels20A and20B, that is, the wind is tending to pull or force the panels20away from the structure to which they are attached, the panels20A,20B will exert the tensioning force on the extrusions66A,66B, respectively by their respective fasteners90. The extrusion66A then applies the tensioning force to the clip70on one end of a panel20primarily via the T-channel74and T-slot65, and, to a lesser extent, via the extrusion component interior wall56and the secondary reinforcement78and79. At the other end of the panel, another extrusion66B then applies the tensioning force to another clip70via the head62and the arm72of the other clip70. The clips70then apply the tensioning forces to the structure via the fasteners35.

It should be noted that use of reinforcing corners52,55and/or57is preferred, but is optional. Likewise, use of the panel stress relief51is preferred, but is optional. In addition, the use of the secondary reinforcement80is preferred, but is optional. In a preferred embodiment, the base53of the clip70extends to the base78of the secondary reinforcement80on one side, and extends past the base71of the tensioning stop arm69on the other side, as shown inFIG. 1. This is not mandatory, however, and the base53may be shortened on either or both sides, as desired or required. In addition, the base53may extend past the secondary reinforcement80, or may extend further past the stop arm69, to provide for more surface area over which to distribute wind loading.

In addition, if a reveal strip87will not be used, then the reveal strip stop57may be eliminated unless desired for corner reinforcement, the component60may be eliminated, and the arm59may be eliminated. Thus, in its basic form, a clip70may comprise a base53, a tensioning stop arm69, and a T-channel74Likewise, in its basic form, an extrusion66may comprise attachment leg54, an interior wall56, and the T-slot65.

A first panel20A and a second panel20B are secured to a structure. Each panel20A,20B has a main portion, a lip, and a hole in the lip. In one embodiment the clip53has a clip base having a first area53A and a second area53B, and there is a generally “T”-shaped track74extending from the first area, and a generally “L”-shaped stop69having a first base71extending from the second area and an arm72extending from the distal end of the first base, the arm generally extending parallel to the clip base and away from the first area. The clip base has a hole between the “T”-shaped track and the “L”-shaped stop and is adapted to accommodate a fastener35to secure the clip to, for example, the structure.

First66A and second66B extrusions are preferably used with the clip. Each extrusion preferably has a generally “U”-shaped base having a first arm59and a second arm62, the second arm having an end60and a base, and the “U”-shaped base is adapted to receive the “L”-shaped stop of the clip. There is a first leg67,56,54extending from the first arm62of the “U”-shaped base and having a hole therein to accommodate a fastener90to secure the extrusion to a panel, the first extrusion to be secured to, for example, the first panel and the second extrusion to be secured to, for example, the second panel. There are also first61and second64generally “L”-shaped extensions extending from the second arm62of the “U”-shaped base, the first extension64extending from the end of the second arm, the second extension61extending from the base of the second arm62. The first extension64, the second extension61and the second arm62form a generally “T”-shaped opening adapted to receive the “T”-shaped track74. In this embodiment the “U”-shaped base of the first extrusion receives the “L”-shaped stop69and the “T”-shaped opening of the second extrusion receives the “T”-shaped track74.

In another embodiment, a panel is secured to a structure having a clip attached thereto, the clip having a clip base and a unitary “T”-shaped protrusion74therefrom. There is a base61,62,63,64, having two “L”-shaped extensions61,64adapted to substantially engage and surround the top of the unitary “T”-shaped protrusion, at least part of one “L”-shaped extension adapted to be engaged between the clip base and the top of the unitary “T”-shaped protrusion. There is also a panel attachment section67,56,54extending from the base and having a hole therein to accommodate a fastener90to secure the apparatus to the panel. In one embodiment a first section67of the panel attachment section extends at approximately 90 degrees from the base. In another embodiment a second section56extends from, and is substantially perpendicular to, the first section. In still another embodiment, a third section54extends from, and is substantially perpendicular to, the second section.

FIG. 2is a bottom view illustration of a panel20with an exemplary embodiment of the present invention. The view is looking at the inside of the panel; that is, the lips21of the panel20are pointing toward the reader. There is preferably a lip21A,21B on each side of the panel20. Four extrusions66are shown, and the view is looking at the bottom of an extrusion; that is, the reader is looking into the T-slot65. Shown are the two feet61,64of the T-slot65, and part of the interior wall56. Two extrusions66A have clips70attached. One extrusion66A has clips70A and70B attached, and the other extrusion66A has the clips70C and70D attached. The clips70have a hole36for the fastener35. Preferably, to save time at the construction site, the panels20are shipped to the desired location with the extrusions66and clips70already attached, as shown.

FIG. 3is a top view illustration of a panel20with an exemplary embodiment of the present invention. The view is looking at the outside of the panel; that is, the lips21of the panel20are pointing away from the reader. Part of the clips70, a portion of the base53, the arm72of the tensioning stop arm69, and a hole36for the fastener35are shown.

FIG. 4is an illustration of the installation of panels20on an exemplary structure50, such as the side of a building. Two J-connectors101are placed on and attached to the structure at two sides, e.g., the bottom side and the left side. In this illustration, the first panel20A is installed by placing it on or proximate to the structure50, and then sliding or moving the panel20A toward the junction of the two J-connectors101. This causes the J-connectors101to engage the extrusions66B of panel20A. Once the panel20A is in place, fasteners35are inserted through the holes36in the clips70and into the structure50. Unlike a clip70, which is preferably but not necessarily a short piece, a J-connector101is preferably, but not necessarily, a long, continuous piece which spans several panels20or even the entire span to which the panels20are to be applied. A J-connector is also commonly referred to as a J-channel.

The next panel20B is installed in a similar manner, but the restraining area86of one extrusion66of panel20B will engage the clip70associated with panel20A, and the restraining area86of another extrusion66of panel20B will engage the lower J-connector101. The next panel (not shown) is installed in a similar manner, but the restraining area86of one extrusion66of this next panel will engage the tensioning stop arm69of the clip70associated with panel20B, and the other extrusion66of this panel20will engage the lower J-connector101. This action preferably continues until a row of panels20has been installed, at which point the last panel20N in the row is installed.

At this point, a plurality of options are available for fastening the last panel20N to the structure50. In a preferred embodiment, the last panel20N of a row differs from the other panels20in that the right-side extrusions of the last panel20N does not have clips attached thereto. Therefore, the clips on the top-side extrusions of the last panel20N are fastened to the structure50in the manner described above, but the right-side extrusions are preferably fastened using a retainer bar103and, preferably but not necessarily, a plastic spacer or shim102.FIG. 6shows a preferred method of attaching an extrusion66A to the structure50. A retainer bar103is inserted into the restraining area86and then fastened to the structure50using a fastener35. It will be noticed that the area86is at a different level than the structure50. Thus, merely inserting the retainer bar103into the area86and fastening the bar103to the structure50could deform or damage the bar103. Therefore, preferably, an optional spacer102is used. Although the spacer102is shown as having an angled face, e.g., the spacer102is a shim, and provides for the bar103entering the area86at an angle, this is merely a preferred embodiment. In an alternative embodiment the spacer102is a flat spacer, e.g., a washer, and is used to raise the bar103to approximately the same height as the area86so that the bar103enters the area86at a smaller angle. It is preferred that there be at least some angle so that the bar103exerts a force tending to hold the extrusion66against the structure50. If the extrusion66is not held somewhat tightly against the structure50then there may be a tendency for the panels to vibrate or rattle.

Returning toFIG. 4, in an alternative embodiment, the last panel20N of a row is the same as the other panels20and the clips on the top-side extrusions and the right-side extrusions (not shown) of the last panel20N are fastened to the structure50in the manner described above for the other panels.

Once a row of panels20has been installed, the next row is begun. The first panel20C of this next row is installed in a similar manner, but one extrusion66of panel20C will engage the clip70associated with panel20A, and the other extrusion66of panel20C will engage the J-connector101on the left side. The next panel (not shown) in the row is then installed, and so on, until that row is complete, at which point the last panel in the row is fastened to the structure50, and the first panel in the next row is begun. This process is repeated until the next to the last row has been installed and fastened.

Although, in the preferred embodiment, the first row is installed, and then the second row is installed, etc., the panels may be installed in different manners if desired. For example, a first column of panels may be installed, and then the second column, and so on. As another example, panel20A may be installed, and the panels may then be installed as diagonals. For example, either panel20B or panel20C is installed, and then the other panel20C or20B is installed, thus completing the first diagonal. Then a panel is installed above either panel20C or to the right of panel20B, thus starting the next diagonal, and so on. One can also start as a row installation, or as a column installations, or as a diagonal installation, and then switch to a different installation method as the work progresses.

For convenience of illustration, only two rows and three columns of panels20are shown. However, in a typical environment, there will be multiple rows and columns.

The panels20of the top row (not shown) preferably, but not necessarily, differ from the other panels20in that the top extrusions of the panels20of the last row do not have clips70attached thereto. The panels20in the top row are therefore also preferably directly fastened to the structure50using the bar103and optional spacer102as described with respect toFIG. 6. In an alternative embodiment, the panels20of the top row are the same as the other panels20and are fastened to the structure50in the same manner as the other panels.

If reveal strips87are to be used then, as two panels are mounted side-by-side, or top-to-bottom, a reveal strip is preferably installed between those panels before proceeding with the installation of the next panel. The reveal strips87may also be installed, however, on a row or a column once the entire row or column is complete. Further, the reveal strips87may also be installed at any time, although installation may become more difficult once the next row or column has been installed and access becomes restricted or limited. The panels20may also be shipped with the reveal strips already installed into the extrusions66A. Reveal strips which are not needed, such as those at the right end of the row or those on the top end of the top row, may then be removed and discarded. Of course, some panels20may be shipped with the reveal strip87installed and some panels may be shipped without reveal strips87. Preferably, a reveal strip87is cut to size in the field from a long length of reveal strip material.

FIG. 5is a side view of an exemplary J-connector101. J-connectors are well known in the art and different styles or embellishments of J-connectors may be used. A J-connector101is designed to interface with an extrusion66as described herein. The specific dimensions of the J-connector will depend upon the specific dimensions of the extrusion66with which it is intended to work. The design and manufacture of a J-connector which functions with an extrusion66will be apparent to one of ordinary skill in the art.

FIG. 6illustrates an exemplary method of attachment of the last panel20of a row to the structure50. This exemplary method is preferably used to attach the right edges of the rightmost panels, such as20N, to the structure50, and to attach the top edges of the panels20of the top row to the structure50.

In an embodiment for use with an exemplary 10 inch by 10 inch panel20, there will be two clips70on a side of the panel, a clip having base53dimensions of approximately 3 inches by 3 inches, and the clip having a height (bottom of component53to top of component79) of approximately 1½ inches.

It will be appreciated from an inspection of the figures that a panel is free to move as required. For example, referring toFIG. 4, once installed, although the clips70are fastened to the surface, the panel20is not. Rather, the panel20can move upward or downward because the tensioning stop arm69and the T-channel74can move up or down within the restraining area86and the T-slot65, respectively. Likewise, the panel20can move sideways because the tensioning stop arm69and the T-channel74can move up or down within the restraining area86and the T-slot65, respectively. Further, as the panel20expands or contracts, the tensioning stop arm69can move further into or move so as to withdraw from the restraining area86. However, note that a panel cannot pull away from the structure50and fall because the panel is always gripped on at least one side, and preferably at least two sides, by the combination of T-channel74and T-slot65. The combination of T-channel74and T-slot65may be considered to be a movable locking mechanism because they will slide relative to each other, but are locked to each other in that they will not separate simply by pulling on the panel or sliding the panel slightly in any direction.

Similarly, in an embodiment for use with an exemplary 10 inch by 10 inch panel20, there will be one extrusion66on each side of the panel, and an extrusion will have a length of approximately 6 inches, will have a height (bottom of component61to top of component51) of approximately 1½ inches, and a width (outside of component54to outside of component67) of approximately ¾ inch.

It should be understood that these dimensions and numbers are merely to illustrate one embodiment and are not limited. Depending upon the panel size, the strength of the structure50, and the weather environment, more or fewer clips70may be required, the size of the clips70may be larger or smaller, and the size of the extrusions66may be larger or smaller. Also, if the panels are rectangular, rather than square, different dimensions and numbers may be appropriate.

The present invention therefore provides an attachment system for securing panels to a structure in a manner which provides for four-way movement of the panel but which prevents the panel from detaching from the structure and falling.

Although the preferred embodiment has been described with respect to use with panels on a structure, the present invention is not so limited. The present invention may be used to attach any desired and appropriate surface treatment to an underlying object. Further, although the preferred environment illustrated herein shows a flat structure, the present invention may also be used with underlying objects which do not have a flat structure, such as, for example, and not by way of limitation, a circular or oval object. In such cases it may be necessary to adjust the angle of the tensioning stop arm and/or the retainer bar to provide for proper engagement with the restraining area.

Although various embodiments of the present invention have been described in detail herein, other variations may occur to those reading this disclosure without departing from the spirit of the present invention. Accordingly, the scope of the present invention is to be limited only by the claims below.