Patent Publication Number: US-9903123-B1

Title: Apparatus for mounting a plurality of panels to a facade

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a novel and useful system for mounting panels to a façade found on building structures and the like. 
     Panels are often used on residential and commercial buildings to cover walls or facades since they have proved to be economical, protective of the edifice, and exhibit a high degree of design versatility, when compared to other coverings. 
     In the past, panel systems have been employed that are categorized as “progressive style systems”. That is to say, that the panels are installed progressively from left to right on the bottom row of a building façade and then upwardly one row at a time in the same direction. The disadvantage of a progressive style panel system is that if a single panel must be removed, many other panels must also be removed prior to gaining access to such single panel. 
     In the past, many systems for mounting wall panels to a surface have been proposed. For example, U.S. Pat. No. 6,588,165 shows an extrusion device for mounting a wall panel that utilizes a base having receiver flanges that accept a clip that snaps into a channel and includes arms that extend over the top of the panel. 
     United States Patent Application Publication 212/0304573 describes a panel clip structure which is attached the backside of the panel and is attached to horizontal joints through a tongue and groove system. A plurality of horizontal caps then keeps a single panel from being easily removed without repositioning adjacent panels on the façade. 
     United States Patent Application Publication 2006/0080939 features a wall panel system that utilizes a plurality of furring strips that are used to fasten panels via fasteners extending through grooves formed in the panel itself. 
     U.S. Pat. No. 6,688,056 describes a demountable wall panel system that utilizes vertical posts, a panel covering, a sealing rail, and an articulating floor channel. A support frame is formed and operatively connected to the articulating floor channel, which is used to secure the frame to a ground surface. 
     U.S. Pat. No. 7,752,818 shows a self-leveling clip which is fixed to the façade and holds a panel by the use of a retentive clip that is engaged by a self-drilling screw between adjacent panels. 
     An apparatus for mounting a plurality of panels to a façade in a non-progressive manner, efficiently and economically, would be a notable advance in the building industry. 
     SUMMARY OF THE INVENTION 
     In accordance with the present application, a novel and useful apparatus for mounting panels to a façade in a non-progressive manner is herein described. 
     The apparatus of the present application utilizes a base or field extrusion having a plate and first and second flanges extending outwardly from the plate. The first and second flanges form an open channel which extends along the plate. Each of the first and second flanges is formed with a resilient leg that extends inwardly toward the channel. The base is held to the façade by a fixing element such as a plurality of screws, rivets, and the like. 
     An extension element or frame extrusion is connected to each of the panels to be mounted to the façade. Each extension element is formed with a platform that is supported by the plate of the base. Platforms on adjacent extension elements connected to adjacent panels are positioned apart from one another and away from the faces of the first and second panels. 
     A fastener is utilized to interconnect adjacent panels. Such fastener is fashioned with a basal portion and first and second arms projecting from the basal portion. The basal portion also is formed with pair of inclined surfaces that are angled relative to the plate. Likewise, the pair of arms extending from the basal portion each includes contact surfaces for engaging the platforms found on the extension elements of adjacent panels. The pair of inclined surfaces of the basal portion of the fastener is dimensioned to slide on a pair of resilient legs of the flanges extending from the plate of the base. Such sliding takes place upon the rotation of the basal portion of the fastener within the channel of the base resulting in a force being exerted on the resilient legs of the flanges. Such force forces the contact surfaces of the pair of arms of the fastener to firmly press downwardly on the platforms of the extension elements connected to adjacent panels and, thus, hold the adjacent panels to the façade. 
     The extension element may also be formed with a slot such that adjacent extension elements connected to adjacent panels allow the insertion of a strip that essentially occupies the space or reveal between panels. The extension element may also be employed to hold corner brackets between panels. 
     A stiffener may also be used in adjacent panels and be at least partially supported by a shelf connected to extension elements found in adjacent panels. Stiffeners provide support to the panels in order to prevent deflection and cracking of the panel. 
     In addition, the extension elements may be located at various distances from the face of the panel to the base, thus, adjusting the depth of the space between panels as may be architecturally specified. 
     It may be apparent that a novel and useful apparatus for fabricating and mounting panels to a facade has been here and above described. 
     It is therefore an object of the present application to provide apparatus for fabricating and mounting a plurality of panels to a façade which results in the mounting of panels in a non-progressive manner. 
     Another object of the present application is to provide an apparatus for fabricating and mounting a plurality of panels to a façade that is capable of being installed quickly and efficiently by the use of a manually operated fastener. 
     Another object of the present application is to provide an apparatus for fabricating and mounting a plurality of panels to a façade in which the reveal between panels includes an adjustable depth or distance between the façade and the panel. 
     Yet another object of the present application is to provide an apparatus for fabricating and mounting a plurality of panels to a façade that is durable and reliable in operation. 
     Another object of the present application is to provide an apparatus for fabricating and mounting a plurality of panels to a façade that allows the installation of panels more quickly than prior art systems. 
     Yet another object of the present application is to provide an apparatus for fabricating and mounting a plurality of panels to a façade that provides for the creation of different reveal styles, multiple panel depth options, and can be used with panels formed of plate or composite material. 
     Another object of the present application is to provide an apparatus for fabricating and mounting a plurality of panels to a façade that exhibits a shape that meets strict hurricane requirements. 
     Yet another object of the present application is to provide an apparatus for fabricating and mounting a plurality of panels to a façade that utilizes a field extrusion or base that may be employed as a field measuring device for subsequently installed panels. 
     The application possesses other objects and advantages, especially as concerns particular characteristics and features thereof which will become apparent as the specification continues. 
     Various aspects of the present application will further be apparent reviewing the following drawings of the invention. 
    
    
     
       DETAILED DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a top partial plan view of the basic element of the present invention adjacent a pair of panels. 
         FIG. 2  is a side elevational view of the fastener employed with the apparatus of the present invention. 
         FIG. 3  is a bottom plan view of the fastener  FIG. 2 . 
         FIG. 4  is a top plan view of the fastener of  FIGS. 2 and 3  being employed with the base adjacent a pair of panels. 
         FIG. 5  is a side elevational view of the fastener and base portions of the apparatus of the present invention shown in  FIG. 4 . 
         FIG. 6  is a side elevational view of an extension element used in conjunction with a single panel. 
         FIG. 7  is a side elevational view of a pair of panels, each having an extension element and a fastener holding such panels to the base. 
         FIG. 8  is a side elevational view of another embodiment of extension element used with the apparatus of the present invention. 
         FIG. 9  is a side elevational view of the extension element of  FIG. 8  used in conjunction with a single panel having a stiffener and the fastener element partially shown. 
         FIG. 10  is a side elevational view of the extension element of  FIG. 8  employed with a filler member creating the mounting of a panel having a greater depth than shown in  FIG. 9 . 
         FIG. 11  is a side elevational view of an alternative embodiment of a fastener which may be employed with the extension element of  FIG. 8 . 
         FIG. 12  is a top plan view of a corner bracket  126  used with a pair of extension elements of  FIG. 8 . 
         FIG. 13  is an isometric view of corner bracket  126  used with a pair of extension elements shown in  FIG. 8 . 
         FIG. 14  is a side elevational view of another embodiment of a fastener in place on the base A. 
         FIG. 15  is a top plan view of the elements shown in  FIG. 14 . 
         FIG. 16  is a top plan view showing a plurality of panels mounted using the apparatus of the present invention. 
     
    
    
     For a better understanding of the invention references made to the following detailed description of the preferred embodiments thereof which we reference to the prior described drawings. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION 
     The apparatus as a whole is shown in the prior described drawings. Many aspects of the present apparatus, which are being sought for patenting, may evolve from the following detailed description of the preferred embodiments thereof which should be referenced to such prior described drawings. 
     An apparatus for mounting a plurality of panels to a façade is depicted in the drawings by reference character  10 , with variation noted by the addition of an uppercase letter. Apparatus  10  includes as one of its elements a base or field extrusion  12 . Base  12  possesses a plate  14 , having surface  15 , and first and second flanges  16  and  18  that extend outwardly from plate  14 , best shown in  FIGS. 1 and 5 . A fixing element  20 , which may take the form of a plurality of rivets, screws, and the like, holds base  12  to façade  22  which may be the side of a building or edifice. Flanges  16  and  18  form a channel  24  therebetween. In the assembled state of apparatus  10 , which will be discussed in detail as the specification continues, channel  24  separates adjacent exemplary panels  26  and  28 , shown in phantom on  FIG. 1 . Plate  14  may be positioned relative to a plane  25 ,  FIG. 5 . With further reference to  FIG. 5 , it may be observed that flanges  16  and  18  include resilient legs  30  and  32 , respectively. Resilient legs  30  and  32  extend toward one another and toward channel  24 . 
     Turning now to  FIGS. 2 and 3 , it may be observed that fastener  34  is depicted. Fastener  34  may be formed of any rigid or semi-rigid material, such as plastic, metal, wood, and the like. Fastener  34  includes a basal or bottom portion  36  having inclined or slanted surfaces  38  and  40 . Inclined surfaces  38  and  39  are angled relative to plane  25  of plate  14  when fastener is in place in the assembled apparatus,  FIG. 7 , which will be detailed hereinafter. Fastener  34  is also fashioned with first and second arms  40  and  42 . Arms  40  and  42  terminate in contact surfaces  44  and  46 . As shown in  FIGS. 4 and 5 , fastener  34  is capable of rotating on surface  15  within channel  24  formed by flanges  16  and  18  extending from plate  14  of base  12  according to directional arrows  48  and  50  of  FIG. 4  and directional arrow  52  of  FIG. 5 . Fastener  34  may also be held at channel  24  by a pop rivet, screw, rivet nut, or bolt extending through fastener  34  and plate  14 . 
     With further reference to  FIG. 6  it may be seen that another part of apparatus  10  is depicted in the form of an extension element or frame extrusion  54 . Extension element  54  is depicted as being connected to first panel  26  via a rivet  56 . Specifically, first extension element  54  is fixed to return  60  which is either integrally formed with panel  26  or attached thereto. Return  60  may also be non-orthogonally angled relative to panel  26 . First extension element  54  is similar to second extension element  62 , depicted in  FIG. 7 , which will be discussed hereinafter. First extension element  54  includes a platform  64  supported above feet  66  and  68 . Feet  66  and  68  lie on plate  14  of base  12  when apparatus  10  is assembled,  FIG. 7 . Cavity or space  83  between feet  66  and  68  may accept gasket material  85  (shown partially in  FIG. 6 ) to resist water intrusion behind panels  26  and  28 . Gasket material  85  will slide with exemplar extension element  54  upon the thermal expansion and contraction of panel  26 . In addition, first extrusion element  54  includes a projection  70  that forms a slot  72 . Moreover, a shelf  74  also extends outwardly from the body  76  of first extrusion element  54 . Legs  78  of first extrusion element  54 , which is shown as fixed to panel  26 , forms a compression recess  80  between legs  78  and return  60 . Stop  82  lies at the terminus of legs  78  and is intended to contact panel  26  to serve as a gauge to determine the distance between panel  26  and platform  64 . A flange  58  projects from extrusion element  54  and may serve as a rest for a panel return longer than panel return  60 . Thus, the depth between panels  24  and  26  and façade  22  may be adjusted. 
     Viewing now  FIG. 7 , it may be apparent that apparatus  10  has been assembled to hold panels  26  and  28  to façade  22 . That is to say, first panel  26  having extension element  54  connected thereto has been placed on plate  14  of base  12 . Likewise, panel  28  having extension element  62  attached to connected return  84  also lies atop plate  14  of base  12 . Panels  26  and  28  are positioned in spaced relationship to one another such that a gap or reveal  86  is formed between returns  60  and  84  of panels  26  and  28 , respectively. Fastener  34  has been rotated or twisted into place such that contact surfaces  44  and  46  of arms  40  and  42 , respectively, lie over and press firmly against or position atop platform  64  of first extension element  54  and platform  88  of second extension element  62 . That is to say, a slight gap may exist between contact surfaces  44  and  46  and platforms  64  and  88 , respectively. In this regard, incline surfaces  38  and  39  of fastener are forced against resilient legs  30  and  32  of flanges  16  and  18  (force arrows  63 ) such that fastener  34  is wedged into channel  24  between flanges  16  and  18 . At the same time, contact surfaces  44  and  46  press firmly against or lie over platforms  64  and  88 , respectively. By this action, panels  26  and  28  are held in place on façade  22  as shown in  FIG. 7 . Arms  40  and  42  of fastener  34  may be lengthened from the image of  FIG. 7  to lie near or against the walls  91  and  93  of extension elements  54  and  62 , respectively. It should also be noted that a strip  90  has been inserted into slots  72  and  92  of first and second extension elements  54  and  62  respectively. Strip  90  serves an aesthetic purpose and is additionally employed to resist water leakage toward plate  14  of base  12 . Shelf  94  of second extension element  62  is shown as supporting a stiffener  95  which contacts the underside of panel  28  and provides support thereto. Shelf  74  of first extension element may also provide accommodation for corner bracket  126 , discussed hereinafter. 
     With further reference to  FIGS. 8 through 10 , another embodiment  10 A of the present invention is shown with a variation of extension elements  54  and  62 . Namely, extension element  96  is illustrated having a body portion  98 , projection  100  with surface  101 , shelf  102 , and platform  104 . Projection  100  includes a sloped end surface  103  that lies along a plane  105  that intersects plane  107  across surface  101 . In addition, a leg  106  terminates in a notch  108 . Extension element  96  is useful in adjusting the depth between the supported panel and the base fixed to the façade. For example,  FIG. 9  shows panel  28  being fixed to extension element  96 . Shelf  102  is used to support stiffener  95  and as an alignment for return leg  84 . Shelf  102  also adds rigidity to extension element  96 . Shelf  102  also gauges the size of stiffener  95 ,  FIG. 9 , as well as adding structural rigidity to extension element  96 . Strip  90 , fastener  34 , and the similar components shown in extension element  62  are partially illustrated in  FIG. 9 . Projection  100  presses against strip  90  forcing strip  90  along return  84 . Moisture is at least partially repelled from entry behind panel  28 , by this expedient. Notch  108  rests against the underside of panel  28 . Thus, the distance between the top of plate  14  and panel  28  is shown as distance “D 1 ”. 
     Turning to  FIG. 10 , it may be observed that extension element  96  has been moved downwardly toward plate  14  such that notch  108  lies a certain distance from panel  28 . A filler member  110  has been placed in notch  108  between panel  28  and notch  108  in this regard. Filler member  110  serves as a gauge or measuring device during fabrication of panel  28  and return leg  60 . Thus, the distance between panel  28  and plate  14  is indicated as distance “D 2 ” which is greater than “D 1 ” of  FIG. 9 . In other words, the depth or distance between panel  28  and plate  14  and façade  22  is adjustable. Notch  108  may also be filled with material to further raise panel  28 . However, stiffener  95  must now be fastened to the underside of panel  28  by the use of mastic layer  112 . 
     Stiffener  95 ,  FIGS. 9 and 10 , may be attached mechanically to shelf  102  by crimping and the like. Stiffener may also be caulked to the underside of panel  28 . Such caulking ideally takes place after painting and oven curing of exemplary extension element  96  and attached stiffener  95 . Again, stiffener  95 , being sized to sandwich between shelf  102  and panel  28 , resists twisting under exerted forces and add rigidity to panel  28 . 
     Further, a fastener  122 ,  FIG. 11 , may be employed with extension element  96 , in substitution for fastener  34  ( FIG. 7 ), such that strip  90  in reveal  86  is capable of riding on the raised top surface or boundary  124  of fastener  122 , and into slots  72  and  92  of extension elements  54  and  62 , since surface  124  is about the same level as plane  107  of surface  101  of projection  100 . It should also be seen that sloped end surface  103  rides on angled side surface  130  of fastener  124 . Sloped end surface  103  may also be placed over surface  130  leaving a gap therebetween. When fastener  124  is twisted into contact with platforms  64  and  88  of extension elements  54  and  62 , respectively, projection  100  presses tightly against strip  90  and the walls of slot  92 ,  FIG. 7 . Such snug fitting helps prevent water from entering beneath panel  28 . Of course the same would hold true with respect to slot  72  of extension  54 . 
     Looking at  FIGS. 12 and 13 , a corner bracket  126 , in the form of an “L” shaped member is illustrated. Corner bracket adjoins extension elements  128  and  130  below panel  132  (partially shown). Corner bracket is fixed to extension elements  128  and  130  via a mechanized fastening. 
     Corner bracket  126  is fastened to the underside of shelves  134  and  136  of extension elements  128  and  130 , respectively, by crimping or the like. Shelves  134  and  136  are similar to shelf  102  of  FIGS. 8-10 . Thus, adjacent panels mounted to façade  22  are formed into a contiguous rigid frame via the use of corner brackets similar to corner bracket  126 . In other words, all panels mounted to façade  22  by apparatus  10  are accurately aligned. 
     With reference to  FIGS. 14 and 15 , another fastener  138  is shown that may be substituted for fastener  34  or fastener  122  in apparatus  10 . Fastener  34  includes arms  138  and  140  that function similarly to arms  40  and  42  of fastener  34 . A shaft such as rivet  144  passes through fastener  138  and bears on resilient legs  30  and  32  of flanges  16  and  18 . 
     In operation, panels  26  and  28  are held to façade  22  by the use of apparatus  10  namely by employment of base  12  held to façade  22  and extension elements such as extension elements  54  and  62  of  FIG. 7  that are connected to panels  26  and  28  respectively. Base  12  and similar bases serve as a field measuring device for panels installed later. Fastener  34  is pressed down into channel  24  formed between flanges  16  and  18  and twisted or rotated within channel  24  such that contact surfaces  44  and  46  firmly press against platforms  64  and  88  of extension elements  54  and  62 , respectively. Such pressing derives from the interaction of inclined surfaces  38  and  39  of fastener  34  against resilient flanges  30  and  32 , force arrows  63 . Stiffener  95  may be employed in certain cases and may be held by shelf  94  of extension element  62  or shelf  74  of extension element  54  (not shown). A reveal  86  is formed between panels  26  and  28  such that strip  90  positioned within slot  72  and  92  of extension elements  54  and  62 , respectively, extends across reveal  86 . With respect to use of extension elements such as extension element  96  as shown in  FIGS. 8-10 , the same operation applies, except that a notch  108  may be used either to support panel  28  or be positioned apart from panel  28 . In the latter case, a filler member  110  may be employed in notch  108  as shown in  FIG. 10 . Again, stiffener  95  may be either held by shelf  102  of extension element  96  or be fastened to the underside of panel  28  by the use of mastic layer  112 . Apparatus  10  permits the thermal expansion and contraction of panels  26  and  28  relative to base  12  via the use of fastener  34 . 
       FIG. 16  represents a plan view showing a plurality of panels  114  mounted to a façade with reveals  116 ,  118 , and  120  shown therein. Such panels are mounted in a non-progressive manner such that any panel of plurality of panels  114  may be removed as needed by simply by twisting or turning fastener  34  between particular panels to remove the same from the flanges of base members adjacent such plurality of panels. 
     While in the forgoing embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill of the art that numerous changes may be made without departing from the spirit and principles of the invention.