Patent Publication Number: US-6216405-B1

Title: Mounting and draining system for prefabricated building panels

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally relates to a mounting and drainage system for prefabricated building panels and, more particularly, to a system for mounting prefabricated building panels onto a building structure and a system for collecting and draining water such as condensation from between the prefabricated building panels and the building. 
     2. Background Description 
     Prefabricated building panels are widely used in the construction of buildings, both small and large. These prefabricated building panels are commonly constructed from a number of materials and most preferably concrete. However, when using concrete to fabricate these panels, it is customary to use reinforced concrete in order to provide rigidity and strength to the concrete panels. It is common practice to use wire mesh for the reinforcement of the concrete panels, and to mount the concrete panels to a framing system which includes vertically aligned studs and upper and lower horizontal tracks connected to the vertically aligned studs. 
     The prefabricated building panels are mounted to a building structure by bolts or welding. However, in order to mount the prefabricated building panels onto a building structure, a crane must first position the panel in its proper location with relation to the building structure, itself The crane must then hold the prefabricated building panel in place while the panels are bolted or welded to the building structure. Typically, the bolting of the prefabricated building panels to the building occurs at a stud of the frame of the prefabricated building panel and the flooring system of the building structure. On the other hand, when welding is used the welding must be performed from both above and below a weld plate attached to the stud. This further delays the mounting of the panel to the building since a welder must perform the weld, including moving all of the welding equipment, from an upper floor to a lower floor level or using two welders and operators. 
     The bolting or welding procedure is one of the most difficult and time consuming tasks of mounting the prefabricated building panel to the building structure. This is because the prefabricated building panel must be first manually aligned onto the building structure while the prefabricated building panel is on the crane. Once properly aligned, the prefabricated building panel must then be bolted at various places on the studs to the building structure, while maintaining the proper alignment between the prefabricated building panels and building structure. In the case of welding, the welding must be performed on both an upper and lower level (as discussed above). Accordingly, the crane must be used to hold the prefabricated building panel until it is properly bolted or welded to the building structure, and thus cannot be used for other purposes. As can be imagined, this system for mounting the prefabricated building panels to the building structure is thus both time consuming and labor intensive, and an inefficient use of heavy machinery (e.g., crane) at the building site. 
     Once the panels are properly mounted, water such as condensation may begin to accumulate between the back surface of the panels and the building structure itself. This is a recently discovered phenomenon, and one which has only been recognized since the water accumulation is otherwise unseen during inspection or during construction of the building. This condensation may damage insulation and drywall on the interior of the building. This will also happen when the caulking between the adjacent panels begins to fail. It is also known that some materials, due to their porosity, may also permit condensation to occur. It is not uncommon for the condensation to penetrate the insulation and damage the interior of the building. 
     Accordingly, what is needed is an efficient temporary mounting system for mounting prefabricated building panels to buildings. What is further needed is a drainage system in order to prevent the accumulation of condensation between the interior building structure and the prefabricated building panels. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the present invention to provide a temporary and a permanent mounting system for mounting a prefabricated building panel to a building. 
     It is a further object of the present invention to provide a drainage system for use with prefabricated building panels so that water accumulation does not occur between the building structure and the prefabricated building panels. 
     It is still a further object of the present invention to provide a mounting system that provides for greater structural integrity between the connection of the prefabricated building panels and the building structure. 
     The present invention provides a temporary mounting and an efficient drainage system for a prefabricated building panel. The prefabricated building panel includes a frame having a plurality of vertical studs and horizontal tracks extending between upper and lower ends of the vertical studs. A section of the prefabricated building panel is mounted to an outer surface of the building frame. The mounting system includes a first mounting plate mounted to one of the vertical studs and a second mounting plate mounted to an adjacent vertical stud. The first and second mounting plates face one another. A landing pad or angle extends between the first and second mounting plates and, in preferred embodiments, is bolted to the facing mounting plates so that it may be removed after the prefabricated building panel is mounted to a building. 
     In the embodiments of the present invention, additional mounting plates and landing pads may be provided. The additional mounting plates may span between selected additional facing mounting plates and are bolted to the selected additional facing mounting plates. Permanent welding plates each having a slot extending substantially through the center are also provided. These slotted plates may be welded or otherwise mounted to the remaining mounting plates (as well as the selected mounting plates). The welding plates include an outward extending portion opposing the wall of the prefabricated building panel and extend past the studs. 
     A landing hook which extends outward from the floor of the building may also be provided. The landing pad mounts to the landing hook, and may be retained by a retaining plate extending from the landing hook. In the further embodiments of the present invention, a bracket is mounted to the floor of the building and an adjustment rod is welded to the landing hook and the bracket. The adjustment rod allows for adjustment of the prefabricated building panel once the landing pad is mounted on the landing hook. 
     The drainage system includes a drain aperture positioned on a lower track between an inner wall of the building and the wall of the prefabricated building panel. A drain tube is connected to a bottom portion of the drain aperture and extends through an aperture of one of the studs, leading to the outside. The drain aperture may be positioned in a trough formed by the lower track. A gutter is formed by caulking the track to the rear surface of the wall and directs condensation from an inner surface of the wall of the prefabricated building panel to the drain aperture. A slot drain may be positioned above the gutter and extends past an edge of the wall of the prefabricated building panel. A caulk seal surrounds an end of the drain tube. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and other objects, aspects and advantages will be better understood from the following detailed description of a preferred embodiment of the invention with reference to the drawings, in which: 
     FIG. 1 shows a mounting system for temporarily mounting a frame of a prefabricated building panel to a building; 
     FIG. 2 shows the mounting system of the present system mounted to a floor of the building; 
     FIG. 3 shows a welding plate for permanent mounting the prefabricated building panel to the building; 
     FIG. 4 shows the welding plate welded to the building; and 
     FIG. 5 shows a drainage system of the present invention. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION 
     For illustrative purposes only a concrete prefabricated building panel mounted to a galvanized steel frame is described herein. However, it is well understood that other prefabricated building panels may be equally used with the present invention. It is further understood that the dimensions of the prefabricated building panels and the frame, including length, width, shape, weight and other variables and quantities specified herein may vary with the type of system contemplated. Therefore, numbers and dimensions specified herein are not to be construed as limitations on the scope of the present invention, but are meant to be merely illustrative of one particular application of the present invention. 
     The Mounting System 
     Referring now to the drawings, and more particularly to FIG. 1, there is shown a mounting system for mounting a frame of a prefabricated building panel to a building. Specifically, the frame  1  of the present invention includes vertically aligned studs  10  and horizontally aligned tracks  11  connected to the studs  10 . In preferred embodiments, the studs  10  are spaced at a distance of approximately two feet. Although not shown, it is obvious to one of ordinary skill in the art that several studs  10  may be aligned within the horizontally aligned tracks  11 , and that any number of spacing patterns (e.g., distances between the studs  10 ) may be used between the studs  10 . 
     Referring still to FIG. 1, mounting plates  12  are facing one another and are mounted between the studs  10 . In preferred embodiments, the mounting plates  12  are mounted to the studs  11  with bolts  16 . Spanning between the mounting plate  12  is a landing pad or angle  14  (hereinafter a landing pad), preferably mounted to the mounting plates  12  with bolts  18 . The landing pad  14  may have a triangular, square, polygonal or other cross section, and may be mounted to the mounting plates  12  using various mounting systems, such as screws or bolts. 
     It is preferred that the landing pad  14  be mounted to the mounting plates  12  with a mounting system that allows the landing pad  14  to be dismounted once the prefabricated building panel is properly mounted to the building structure. Also, in the embodiments of the present invention, the studs  10  and tracks  11  are galvanized heavy gauge steel, and the mounting plates  12  and the landing hooks  14  are A36 grade steel. However, it is important to note that other materials used for the frame  1  and other components can be used depending on the particular application being used with the prefabricated building panel of the present invention. 
     FIG. 2 shows the landing pad  14  mounted to a floor  20  of a building. In preferred embodiments, a landing hook  15  extends outward from the floor  20  such that the landing pad  14  can be mounted thereon. A retaining plate  16  extends from the landing hook  15  and retains the landing pad  14  on the landing hook  15  until the prefabricated building panel can be mounted onto the floor  20  of the building. It is important to note that the landing hook  15  may be placed at other locations on the building structure such as a vertically aligned beam or other structure, while still maintaining its purpose of holding the prefabricated building panel to the building while the prefabricated building panel is being mounted thereto. 
     Since the landing pad  14  is retained on the landing hook  15 , a crane does not have to hold the prefabricated building panel in alignment with the floor  20  while it is being mounted thereto. Thus, the crane can now be utilized for other purposes, such as lifting and mounting another prefabricated building panel to the building structure. 
     Referring still to FIG. 2, in the embodiments of the present invention, a bracket  18  having a slot  18   a  can be mounted to the floor of the building. Attached between the landing hook  15  and the bracket  18  is an adjustment rod  22 . The adjustment rod  22  can adjust the positioning and/or alignment of the prefabricated building panel prior to final mounting to the building structure. Accordingly, the adjustment rod  22  helps to facilitate the alignment and mounting of the prefabricated building panel to the building structure. 
     FIG. 3 shows a weld plate  25  mounted to the mounting plate  12 . In the preferred embodiment, the weld plate  25  includes a slot  25   a  and is welded to the mounting plate  12  at weld areas  26 . The slot  25   a  allows the weld to be located in a center portion of the weld plate  25  and provides structural integrity as discussed in detail with reference to FIG.  4 . As seen in FIG. 3, the weld plate  25  extends past an edge of the stud  12  opposing a floor slab  27  at extended portion  25   b.  Depending on the particular application, the weld plate  12  may be welded or otherwise mounted (e.g., bolted) to the mounting plate prior to, simultaneously with or after the landing pad  14  is placed on the landing hook  15 . Also, in the embodiments, the weld plate  25  may be located above or below the landing pad  14 , or may be mounted to mounting plates  12  that do not have the landing pad  14  mounted thereto. Also, the weld plate  25  may be equally used without the benefit of the landing pad  14 . In the latter instance, the prefabricated building panel must be positioned and held in place by the crane prior to being mounted to the building structure. 
     FIG. 4 shows the weld plate  25  welded to the floor  20 . Specifically, once the prefabricated building panel is properly positioned, the extended portion  25   b  of the weld plate  25  is welded to an edge angle  30  on an edge of the floor  20 . The weld plate  25  is welded at welding location  32 . At this time, the weld plate  25  may also be welded to the mounting plate  12  at locations  26  (FIG.  3 ). The weld areas of the slot  25   a  of each weld plate  25  provides for more surface area for the welds thus providing a better and more robust weld area, and further permits welding to be performed from one location. The weld plates  25  may be located on every stud  10  or spaced on every other stud  10  or other spacing patterns depending on the size and weight of the prefabricated building panel and other engineering criteria. 
     By using this system, the frame  1  can be mounted to the floor  20  from one location (e.g., on top of the floor), and does not have to be welded at a bottom edge  25   c  of the weld plate  25 . Thus, a welder does not have to weld the weld plate  25  from above and below the weld plate  25  in order to properly mounted the prefabricated building panel to the building structure. Now, the welder needs only to weld the weld plate  25  to the building structure and the studs  10  of the prefabricated building panel from the floor  20  of the building structure at locations  26  and  32 . 
     The Drainage System 
     FIG. 5 shows the drainage system of the present invention. It is well known to one of ordinary skill in the art that the mounting system and the drainage system may or may not be used together in the prefabricated building panel. Specifically, opposing sidewalls  11   a  of the lower track  11  form a gutter, and a drain aperture  30  is positioned within the gutter. The drain system further includes a drain tube  31  connected to the bottom of the drain aperture  30  and extends through an aperture  10   a  on the stud  10 . In further embodiments, the drain tube  31  further extends through a caulking  36  placed between adjacent prefabricated building panels. Surrounding the drain tube  31  at the caulking  36  is preferably a caulk seal  32 . In the preferred embodiment, the drain tube  31  is a PVC drain tube having approximately one half inch diameter and extending to an outer portion of the building. 
     Caulking  33  extends the entire length of a sidewall  11   a  of the lower track  11  and, in preferred embodiments, bridges the space between the sidewall  11   a  of the lower track  11  and the prefabricated slab. A slot drain  34  is positioned above the caulking  33  and extends onto an adjacent prefabricated slab  27 . Water which may leak through caulking  36  is guided to the gutter by the slot drain  34  and then into the drain aperture  30  through the drain tube  31  and to the outside. Similarly, any condensation that may form on the inner surface of the prefabricated slab  27  will drain to the gutter and then into the drain aperture  30  through the drain tube  31  and to the outside. Thus, water will not accumulate within the gutter of the frame. 
     While the invention has been described in terms of a single preferred embodiment, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims.