Abstract:
A Dry Joint Wall Cladding Attachment System for mounting aluminum composite material (ACM) panels on a building substructure utilizing a non-progressive installation method which permits installation of such panels from any direction or location on the building structure. The present system and method of use provides structural elements including spring clips integrated with each ACM panel that enable a non-progressive panel installation sequence starting from any given location on a building facade even when some sections of the facade are not complete or otherwise not ready for progressive panel installation. Using a method of the present invention this is accomplished by the insertion of a reveal strip fabricated from a suitable material into a reveal cavity between adjacent panels for engagement with the integrated spring clips at any time after the panels are installed. The reveal strips are utilized to protect an underlying grid of mounting brackets and fasteners.

Description:
BACKGROUND OF INVENTION 
     Field of Invention 
     The present invention relates to building construction and, more particularly, to a mounting system for building facades formed of sheet metal panels such as aluminum composite material (ACM) and other suitable building materials, which are installed on an underlying mounting grid applied to a building structure that enables convenient installation, repair or replacement of individual panels. 
     The use of aluminum composite material (ACM) panel systems for exterior building facades are known in the prior art. Such ACM panels are typically made from two sheets of aluminum material bonded to a thermoplastic core. ACM panels are strong and lightweight and can be applied to new building facings or during remodeling of an existing structure. ACM panels can be fabricated to conform to very complex and intricate building wall designs. 
     ACM wall cladding systems are typically of two types, namely, Wet Joint Systems comprised of caulked or rubber gasket joints or, alternatively, Dry Joint Systems, which do not use caulking or rubber gaskets. Wet Joint Systems rely upon adhesive or caulking to seal the wall panels from weather elements. However, under exposure to cold, heat and moisture such Wet Joint Systems can fail. To remedy this situation new caulking must be reapplied to protect the building and to create watertight joints. Dry Joint Systems are comprised of assembled wall panels that do not have water tight joints and rely on weather barriers (i.e. underlayment materials) to protect the building structure from air and water intrusions. 
     Both prior art Wet Joint and Dry Joint wall cladding systems typically include individual wall panels which are mounted on extruded aluminum frame members attached to the underlying building substructure with fasteners in a grid-like pattern. During the installation process a filler strip of ACM material is typically installed in the gap or so-called reveal between adjacent wall panels. Most wall cladding systems require filler strips to be installed into a slot formed in the extruded aluminum frame members in a continuous or so-called “progressive” manner (i.e. as each wall panel is installed) before installation of the next adjacent wall panel. However, such a “progressive” installation method requires complete removal of installed panels in reverse order to replace a ground level panel that has been damaged, for example, by vehicular impact, other accidental damage or vandalism. 
     Thus, the present Dry Joint Wall Cladding Attachment System has been developed to provide a “non-progressive” installation system and method of use which includes novel structural elements and offers additional advantages over the prior art. 
     DESCRIPTION OF RELATED PRIOR ART 
     U.S. Pat. No. 4,021,987, granted May 10, 1977, to Fritz Schnebel, et al., discloses the use of tie beams and girders for use in retaining facades constructed from prefabricated elements. A facade is mounted thereon simply by attaching a retaining strip and interposing packing elements, whereupon the tie beams and girders of aluminum are capable of absorbing horizontal or vertical displacements of the facade within a specific tolerance range. 
     U.S. Pat. No. 4,452,029, granted Jan. 5, 1984, to Ronald D. Sukolics, provides a clip having an inward force or pressure, wherein panel interlocks, which are ridges running longitudinally along the length of side, press against the panel member, having grooves on the inner sides of the turned down edges. (Column 2, lines 41-48) The citation further states, at Column 2, line 46: “An insert strip  26  is located between turned down edges  22  such that grooves  24  are maintained in cooperation with interlocks  18  and  20 .” 
     U.S. Pat. No. 5,842,315, granted Dec. 1, 1998, to William H. Porter, discloses an insulated structural panel with a flat insulating core, first and second outer facings attached to opposed lateral surfaces of the insulating core, with a liner, elongated metal strip disposed between and attached to the insulating core and the first outer facing to the extended length of the panel for increasing the bending strength of the panel. 
     U.S. Pat. No. 6,470,629, granted Oct. 29, 2002, to R. M. Haddock, discloses an apparatus for securing members to a surface. The apparatus includes a mounting clamp, a mounting adaptor, a panel support member and a fastener. The panel support member and the mounting adaptor are slidably interconnected to one another. The mounting adaptor is fixedly interconnected to the mounting clamps using the fastener. The mounting adaptor may also include an area of reduced strength to permit the controlled failure of the apparatus in response to excess loading. The panel support member may be adapted to receive a panel. When installed on a surface, the apparatus obscures the view of mounting devices or equipment that may also be secured to the surface. 
     U.S. Pat. No. 6,817,147, granted Nov. 16, 2004, to Douglas B. MacDonald, discloses a clip for panel trim that is a U-shaped flexible member defining a base and extending arms with end portions extending inwardly for insertion in openings of a partition frame member to retain the clip on the frame so that the base is separated from the frame for routing of utility lines on the partition frame member and through the clip. 
     U.S. Pat. No. 8,347,569, granted Jan. 8, 2013, to J. Andrew McIntyre discloses a self-leveling structural element in a non-progressive ACM attachment system, a U-shaped retentive clip having a base and two upwardly extending arms that are forced apart by the installation of a self-drilling screw, the retentive clip with screw coacting with an extruded frame to mount and retain a plurality of aluminum composite material (ACM) panels in a coplanar manner for a non-progressive system that enables removal of individual panels for replacement or repair. Although this ACM mounting system provides for non-progressive installation of panels, a plurality of fasteners must be separately installed in the reveal cavity between adjacent panels to secure each panel to the underlying frame assembly necessitating additional steps in the installation/removal process. 
     While these devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not disclose the novel features of the present Dry Joint Wall Cladding Attachment System. The present system provides structural elements including novel spring retaining clips that allow the ACM panels to be installed in a non-progressive manner, that is, such panels can be started from any direction on the building facade. The ability to install ACM panels from any direction allows a continual progress of installation, even when sections of the building substrate are not ready or other job conditions do not allow for panel installation. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention is a Dry Joint Wall Cladding Attachment System for mounting aluminum composite material (ACM) panels or other similar panels on a building structure utilizing a non-progressive installation method, which allows installation of such panels from any direction on the building structure and convenient removal of individual panels. 
     The present system and method of use provides structural elements including novel spring clips integrated with each ACM panel that allow a non-progressive installation sequence starting from any given location on a wall facing even when some sections of the wall facing are not complete or otherwise ready for progressive panel installation. Using the present method this is accomplished by the insertion of a reveal strip fabricated from ACM material or other suitable material into the so-called reveal cavity between adjacent panels for engagement with the integrated spring clips at any time after the panels are installed on the wall facing. The reveal strip covers the underlying mounting hardware and provides convenient access for panel repair/removal. The installation of the reveal strip is done by manually inserting it into the reveal cavity thereby compressing the integrated spring clips installed on each panel. Once the reveal strip is properly positioned inside the reveal cavity, the spring clips return to a relaxed condition locking the reveal strip in place without the need for additional fasteners to complete the panel installation. 
     Each panel defines a drainable compartment that limits water penetration and also provides for air infiltration to prevent moisture build up under adverse weather conditions. Moisture penetration into the present system is dependent on a properly selected water barrier that is appropriate for the geographic area. 
     There has thus been outlined, rather broadly, the important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 
     Those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods, and systems for carrying out the purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     Other features and technical advantages of the present invention will become apparent from a study of the following description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The novel features of the present invention are set forth in the appended claims. The invention itself, however, as well as other features and advantages thereof will be best understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures, wherein: 
         FIG. 1  is a perspective view of section of a building façade showing a prior art Wall Cladding System installed thereon and is labeled Prior Art; 
         FIG. 2  is a perspective view of an enlarged section of the prior art Wall Cladding System of  FIG. 1  comprised of a plurality of ACM panels collectively held in place by a frame assembly and is labeled Prior Art; 
         FIG. 3  is a perspective view of a typical welded intersection of the horizontal and vertical frame members comprising a frame assembly whereon ACM panels are retained and is labeled Prior Art; 
         FIG. 4  is an exploded perspective view of the typical welded intersection of the horizontal and vertical frame members shown in  FIG. 3  and is labeled Prior Art; 
         FIG. 5  is an exploded perspective view of the ACM panels inserted into the extruded frame members and clamped by prior art panel-retaining clips and is labeled Prior Art; 
         FIG. 6  is a perspective view of a prior art panel-retaining clip with its associated self-drilling mounting screw and is labeled Prior Art; 
         FIG. 7  is a front elevation view showing a section of the Dry Joint Wall Cladding Attachment System of the present invention including an array of ACM panel assemblies mounted on an underlying grid layout; 
         FIG. 8A  is a perspective view of a section of a panel mounting bracket of the present system; 
         FIG. 8B  is a cross-sectional view of the panel mounting bracket of  FIG. 8A ; 
         FIG. 9  is a rear perspective view of an ACM panel assembly for use with the present system; 
         FIG. 10A  is a perspective view of a section of a panel frame side member utilized to construct each panel frame subassembly of the present system; 
         FIG. 10B  is a cross-sectional view of a section of the panel frame side member shown in  FIG. 10A  illustrating the cross-sectional profile thereof; 
         FIG. 11A  is a perspective view of a curved spring clip shown in a relaxed condition and utilized in each ACM panel assembly of the present system; 
         FIG. 11B  is a perspective view of the curved spring clip of  FIG. 11A  shown in a compressed condition; 
         FIG. 12A  is a perspective view of an angular spring clip shown in a relaxed condition and utilized in each ACM panel assembly of the present system; 
         FIG. 12B  is a perspective view of the angular spring clip of  FIG. 12A  shown in a compressed condition; 
         FIG. 13  is a cross-sectional view taken through the juncture of two adjoining panel assemblies of the present system attached to a building substructure and secured with a fastener; 
         FIG. 14A  is a perspective view of a section of an ACM filler strip for insertion in the reveal cavity between adjoining ACM panel assemblies of the present system; 
         FIG. 14B  is a cross-sectional view of a section of a reveal strip of  FIG. 14A  showing a beveled edge formed thereon; and 
         FIG. 15  is a partially cutaway composite view of an array of ACM panel assemblies of the present system showing the internal arrangement of the spring clips attached to the panel assemblies and a sequential illustration of a reveal strip installation procedure. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. 
     Prior to describing the novel features of the present invention in detail, it may be beneficial to briefly review the structure and installation methods of wall cladding systems of the prior art in order that the description of the present invention that follows may be better understood and that the present contribution to the art may be better appreciated. 
     With further reference to the drawings there is shown therein an Aluminum Composite Material (ACM) Wall Cladding System of the prior art, indicated generally at  200  and illustrated in  FIG. 1 . It is reiterated that such ACM Wall Cladding Systems are typically of two types, namely, Wet Joint Systems comprised of caulked or rubber gasket joints or, alternatively, Dry Joint Systems which do not use caulking or rubber gaskets. Either type of Wall Cladding system may utilize an underlying water barrier (not shown) comprised of an engineered plastic sheet or other suitable material known in the industry. 
     Both such prior art Wet Joint and Dry Joint Wall Cladding Systems include individual wall panels  215  ( FIG. 2 ) which are mounted on an extruded aluminum frame assembly, indicated generally at  205 , as shown in  FIG. 3 , and attached to an underlying building structure  250  ( FIG. 4 ) with fasteners. Frame assembly  205  is comprised of a plurality of vertical frame members  205   a  and horizontal frame members  205   b  joined at an intersection  210  and arranged in perpendicular relation in a rectangular grid pattern as more clearly shown in exploded view in  FIG. 4 . The collective cavities defined by the frame assembly  205  are configured to receive a plurality of panels  215 , wherein the side members of the panels are inserted into the frame assembly  205  such that each adjacent panel  215  will lie in a coplanar manner. 
     Referring now to  FIGS. 5 and 6 , such prior art Wall Cladding Systems typically require some type of deformable clip  100  comprising a structural element for retaining such panels  215  to a frame member assembly  205 . Such prior art clips  100  are typically formed into suitable extruded lengths for ease in handling. The extruded lengths are then sheared into a plurality of clips  100  of shorter lengths. Orthogonal to the base  115  of the prior art clip  100  illustrated are two arms  120 , each having beveled planes  125  on inward facing surfaces thereof ( FIG. 6 ). 
     In the prior art a self-drilling screw  105  is typically used to secure the clip  100  during the installation by passing through a hole (not shown) in the base  115  of the clip. The screw  105  is typically a flat head self-drilling screw having an included angle that matches the included angle formed by the beveled planes  125  of the clip  100  shown in  FIG. 6 . A fastener hole (not shown) is formed through the base  115  for removably fixing the clip  100  to its supporting frame  205 , via mounting screws  105 . After the panels  215  are seated into the frame  205  and retained by the clips  100 , a gasket  220  is inserted into the slotted opening between adjacent panels  215  to complete the installation of the Wall Cladding System  200  as shown in  FIG. 5 . 
     In many prior art Wall Cladding Systems the removal of a single panel  215  for repair or replacement requires the removal of an entire section of the ACM facing because the panels  215  are interconnected. The use of the deformable clip  100  of the type disclosed in U.S. Pat. No. 8,347,569 to J. Andrew McIntyre, for example, provides a Wall Cladding System  200  wherein each individual panel is removable for replacement or repair. However, the above-referenced non-progressive system of U.S. Pat. No. 8,347,569 does not provide the novel structural features and technical advantages of the present invention, which will now be disclosed in detail. 
     Referring now to  FIG. 7  there is shown therein a Dry Joint Wall Cladding Attachment System, indicated generally at  10 , for mounting an array of aluminum composite material (ACM) panel assemblies, indicated generally at  25 , each including an ACM panel  15  and a panel frame subassembly, indicated generally at  35  ( FIG. 9 ), which is mechanically attached by appropriate fasteners about the periphery of each panel  15  in advance of installation. As in the prior art systems described hereinabove, an optional moisture protection barrier  75  ( FIG. 15 ) of an engineered plastic sheet or other suitable water barrier may be employed with the present system  10  and applied to the underlying building substructure in advance of installing the present system if appropriate for the geographic area. 
     The present wall mounting grid comprises a plurality of extruded aluminum, panel mounting strips or brackets  30  of various lengths which are mounted to an underlying building substructure  50  ( FIG. 13 ) with appropriate fasteners such as screws  32  ( FIG. 13 ) at predetermined locations in a pattern designed to receive panel assemblies  25  during installation. The layout of the mounting brackets  30  is correlated with the dimensions of the individual panel assemblies  25  to be installed. 
     As shown in  FIGS. 8A-8B  brackets  30  are configured as a flattened member  30   a  with an integral channel portion  30   b  extending along the entire length thereof, which functions as a spacer to stand the brackets  30  off the building substructure to a dimension “D” to permit sufficient clearance for engagement with the panel frame subassembly  35  ( FIG. 9 ) in order to hold the panel assemblies  25  to the wall facing in a coplanar manner as shown in  FIG. 13 . 
     Referring to  FIGS. 10A-10B  each panel frame subassembly is constructed of individual extruded side members  36  ( FIG. 10A ) of a predetermined length and design having a cross-sectional profile as indicated generally at  37  ( FIG. 10B ). Side members  36  are configured to engage brackets  30  during installation and to receive spring clips  40 ,  45  attached thereto as shown more clearly in  FIG. 9 . 
     In a preferred construction side members  36  of a predetermined length are fabricated to include mitered corners at any desired angle, which are mechanically attached by suitable fasteners to form a rectangular frame subassembly  35  as illustrated in  FIG. 9 . A plurality of spring clips  40 ,  45  ( FIGS. 11A and 12A ) are installed within a channel feature as at  36   a  formed along the length of each side member  36  using suitable fasteners such as rivets  42  in the arrangement shown in  FIG. 9 . 
       FIG. 13  shows a cross-section view of a typical panel assembly  25  installation taken through a dry joint at the juncture of two adjoining panel assemblies  25  of the present system. It will be appreciated that panel assemblies  25  are attached to a building substructure  50  by installing mounting clips  30  ( FIGS. 8A-8B ), which are secured to the substructure with fasteners such as screws  32 . It can be seen that the side member  36  of each panel assembly  25  engage the mounting clips  30  as illustrated to secure the panel assemblies in coplanar relation on the building substructure  50 . 
     Still referring to  FIG. 13  it will be appreciated that a reveal strip  55  is captured in the reveal cavity as at  60  between the adjoining panel assemblies  25  and secured in place with the spring clips  40 ,  45 . As shown in  FIGS. 14A-14B  reveal strip  55  is fabricated as an elongated rectangular member ( FIG. 14A ) into suitable lengths for ease in handling, which are then sheared into a plurality of strips  55  of shorter lengths. In a preferred embodiment reveal strips  55  are constructed from the same ACM materials as panels  15 . However, other alternative materials including engineered plastics are suitable for this application. 
     Reveal strips  55  include a beveled edge  55   a  formed along one lateral edge extending along the entire length thereof. Beveled edge  55   a  functions to guide reveal strips  55  during insertion into the reveal cavity  60  wherein strips  55  are locked into position as hereinafter explained in further detail. 
     Referring to  FIG. 15  there is shown an array of panel assemblies  25  including a plurality of spring clips  40 ,  45  mounted as shown on a building substructure  50  using the present system  10 . Utilizing a method of the present invention a plurality of mounting brackets  30  are attached to the building substructure  50  in perpendicular relation and arranged in a grid pattern at regular intervals corresponding to the dimensions of the individual panel assemblies  25  to be installed. Each panel assembly  25  is attached to substructure  50  by engagement of the rearward facing edges of each side member  36  within each panel frame subassembly  35  with mounting brackets  30  as shown in  FIG. 13 . 
     When the desired arrangement of panel assemblies  25  is achieved, a reveal strip  55  of a predetermined length is installed in the reveal cavity as at  60  between adjoining panel assemblies as illustrated in the composite reveal strip insertion sequence shown in  FIG. 15  to complete the installation. Initially, the beveled edge  55   a  of the reveal strip  55  is inserted into the reveal cavity  60  in generally perpendicular relation to the ACM panels  15  into contact with spring clips  40 ,  45  as shown by directional arrows  65 . It will be understood that the function of the spring clips  40 ,  45  is initially to guide the reveal strip  55  into its installed position in the reveal cavity  60  and then to lock the reveal strip into such position. 
     Still referring to  FIG. 15  this is accomplished by pushing the reveal strip  55  inwardly against the spring bias of curved spring clips  40  to deform such clips  40  to a compressed condition (shown by broken line  43  in  FIG. 11B ). Next, the reveal strip  55  is partially rotated (shown by directional arrows  65  in  FIG. 15 ) about its longitudinal axis into contact with angular spring clips  45  to deform such clips  45  to a compressed condition (shown by broken line  47  in  FIG. 12B ). 
     While maintaining manual pressure inwardly against the spring bias of angular spring clips  45  and continuing partial rotation (shown by directional arrows  65  in  FIG. 15 ) against the spring bias of angular spring clips  45 , reveal strip  55  slides past clips  45 , which return to a relaxed condition and the reveal strip snaps into the position (shown broken outline in  FIG. 15 ) wherein it is locked between side members  36  of adjoining panel assemblies  25 . Reveal strips  55  function to cover the fasteners such as screws  32 , which secure the underlying mounting brackets  30  to the building substructure  50 . 
     Of course, various other configurations of spring clips  40 ,  45  may be devised to function in guiding the insertion and locking of the reveal strips  55  into position. The embodiments of spring clips  40 ,  45  disclosed herein are considered illustrative and not restrictive in any sense. Thus, various alternative designs for spring clips  40 ,  45  are considered within the scope of the present invention. Accordingly, other materials such as engineered plastics, rubber and coated steel having similar deformable characteristics can be utilized to fabricate spring clips  40 ,  45 . 
     Although not specifically illustrated in the drawings, it should be understood that additional equipment and structural components will be provided as necessary and that all of the components described above are arranged and supported in an appropriate fashion to form a complete and operative Dry Joint Wall Cladding Attachment System and Method of Use incorporating features of the present invention. 
     Moreover, although illustrative embodiments of the invention have been described, latitude of modification, change, and substitution is intended in the foregoing disclosure, and in certain instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of invention.