Source: http://www.google.com/patents/US7614191?dq=7350717
Timestamp: 2016-02-07 12:04:46
Document Index: 36878033

Matched Legal Cases: ['Application No. 2', 'Application No. 2', 'Application No. 2', 'Application No. 2', 'Application No. 2', 'Application No. 2']

Patent US7614191 - Method and apparatus for erecting wall panels - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsThe wall panel system of the present invention includes an attachment member that is received in a groove in a panel to align and hold the panel in place on a perimeter framing member....http://www.google.com/patents/US7614191?utm_source=gb-gplus-sharePatent US7614191 - Method and apparatus for erecting wall panelsAdvanced Patent SearchPublication numberUS7614191 B2Publication typeGrantApplication numberUS 10/138,444Publication dateNov 10, 2009Filing dateMay 2, 2002Priority dateDec 12, 1997Fee statusPaidAlso published asCA2255535A1, CA2255535C, US5916100, US6330772, US7272913, US7516583, US20020026758, US20020134034, US20030192270, US20070094965Publication number10138444, 138444, US 7614191 B2, US 7614191B2, US-B2-7614191, US7614191 B2, US7614191B2InventorsEverett Lee MitchellOriginal AssigneeElward Systems CorporationExport CitationBiBTeX, EndNote, RefManPatent Citations (98), Non-Patent Citations (48), Referenced by (14), Classifications (16), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetMethod and apparatus for erecting wall panels
US 7614191 B2Abstract
The wall panel system of the present invention includes an attachment member that is received in a groove in a panel to align and hold the panel in place on a perimeter framing member.
(a) a first panel having a predetermined groove in a surface thereof, and a peripheral edge;
(b) a first perimeter framing member including two opposing surfaces forming a corresponding first pocket for receiving the peripheral edge of the first panel; and
(c) a first attachment member including a first bearing surface and a second bearing surface wherein:
(1) the first bearing surface for being received in the predetermined groove in the surface of the first panel, the predetermined groove provided prior to engagement of the first bearing surface with the first panel;
(2) the second bearing surface for pressing against a portion (P) of the first perimeter framing member outside of the first pocket; and
(3) at least a portion of the first attachment member for extending substantially rigidly from the first bearing surface to the second bearing surface, each of the first and second bearing surfaces contributing to inhibiting the first panel from disengaging from the first pocket.
2. The wall system of claim 1, wherein the first panel includes at least one of wood, plastic, metal, ceramics, masonry, and composites thereof.
3. The wall system of claim 1, wherein the first attachment member has an extent with a predetermined rigidity for inhibiting a deformation of the extent from a predetermined shape;
wherein the inhibiting of deformation of the extent operably contributes to the first attachment member remaining in a position where:
(i) the first bearing surface is received in the predetermined groove, and
(ii) the second bearing surface is pressed against the portion P.
4. The wall system of claim 3, wherein the first attachment member is “L” shaped.
5. The wall system of claim 3, wherein the first panel is folded such that the peripheral edge is offset from a face of the first panel.
6. The wall system of claim 3 further including:
(d) a second panel having third and fourth panel surfaces and a groove in the third panel surface;
(e) a second perimeter framing member having opposing first and second pocket surfaces for defining a second pocket for receiving a peripheral edge of the second panel; and
(f) a second attachment member having a first bearing surface to be received in the groove in the third panel surface, and having a second bearing surface for engaging a portion (Q) of the second perimeter framing member;
wherein when the first bearing surface of the second attachment member is received in the groove in the third panel surface, and the second bearing surface of the second attachment member is coupled to the portion Q, the first and second bearing surfaces of the second attachment member contribute to inhibiting the second panel from disengaging from the second pocket; and
wherein the first and second perimeter framing members are operably connected together for fixedly positioning the first and second panels adjacent to one another, wherein each of the first and second perimeter framing members is provided as a single unit prior to the first and second perimeter framing members being connected together.
7. The wall system of claim 6, wherein the first and second panels are spaced apart from one another by a channel, and the channel includes opposing first and second sides, each of the first and second sides provided by a different one of the first and second perimeter framing members.
8. The wall system of claim 6, wherein the first and second perimeter framing members movably engage one another.
9. The wall system of claim 6, wherein the second bearing surface of the second attachment member engages a receiving surface of the second perimeter framing member and the receiving surface is located outside of the second pocket.
10. The wall system of claim 6, wherein when the first and second perimeter framing members are operably connected together, each of the first and second pockets are spaced apart from one another by a gap bounded by opposing first and second sides, wherein the first side is exterior to the first pocket of the first perimeter framing member, and the second side is exterior to the second pocket of the second perimeter framing member.
11. The wall system of claim 10, wherein a corresponding surface for defining each of the first pocket and the second pocket is positioned between the first and second attachment members.
12. The wall system of claim 6, wherein for each of the first and second panels, the panel is folded such that a portion of the panel, positioned in a corresponding one of the first pocket and the second pocket, is transverse to a face of the panel.
13. The wall system of claim 6, wherein at least one of the first and second attachment members is metal.
14. The wall system of claim 6, wherein at least one of the first and second attachment members attaches its corresponding one of the first and second perimeter framing members to the corresponding one of the first and second panels after the corresponding panel is positioned within the pocket of the corresponding one of the first and second perimeter framing members.
15. The wall system of claim 6, wherein at least one peripheral edge of one of the first and second panels abuts a back wall of a respective one of the first pocket and the second pocket.
16. The wall system of claim 1, wherein the pocket includes sidewalls that are fixedly spaced apart prior to a securing of the first panel therein.
17. The wall system of claim 1, wherein the first attachment member has an extent with a predetermined rigidity for inhibiting a deformation of the extent from a predetermined shape.
18. The wall system of claim 1, wherein the first attachment member includes an operably non-deformable extent extending from the predetermined groove to a portion outside of the pocket, wherein a persistent force applied to the extent from outside of the pocket maintains the first bearing surface in the predetermined groove;
wherein the force is in a direction operably traverse to a direction of the first panel extending out of the pocket.
19. The wall system of claim 18, further including a fastener for operably coupling the first attachment member to the first perimeter framing member, the fastener being effective for pressing the second bearing surface against the portion P of the first perimeter framing member.
20. The wall system of claim 1, wherein the first attachment member induces a substantially greater total force for pressing the first panel against one of the two opposing surfaces of the first pocket, than a total force the first attachment member induces against the other of the two opposing surfaces of the first pocket.
21. The wall system of claim 3, wherein the extent extends from the first bearing surface to the second bearing surface.
22. A wall system, comprising:
(a) a panel having a groove in a first panel surface of the panel;
(b) a perimeter framing member having two opposing surfaces for forming a pocket for receiving a peripheral edge of the panel; and
(c) an attachment member for aligning and maintaining the peripheral edge in the pocket, the attachment member including first and second bearing surfaces, the first bearing surface to be received in the groove in the first panel surface, and the second bearing surface for engaging a surface of the perimeter framing member, wherein at least a portion of the attachment member is to be positioned between: a surface (S) of the opposing surfaces of the pocket, and a surface of the panel;
wherein the second bearing surface is received in a groove located outside of the pocket when the panel is engaged with the attachment member.
23. The wall system of claim 22, wherein a surface (S0) that opposes S for forming the pocket is such that S0 contacts a second surface of the panel when the panel is engaged with the attachment member, and the surface S is mostly spaced apart from the panel.
24. The wall system of claim 23, wherein the two opposing surfaces are substantially parallel to one another and to the first panel surface, when the attachment member is engaged with the panel;
wherein the attachment member induces a substantially greater total force for pressing the panel against one of the two opposing surfaces of the pocket, than a total force the first attachment member induces against the other of the two opposing surfaces of the pocket.
25. The wall system of claim 22, wherein the panel is folded such that the peripheral edge of the panel is offset from a face of the panel.
26. The wall system of claim 25, wherein the pocket opens towards the face of the panel.
27. A wall system, comprising:
(a) a panel having a groove in a first surface of the panel;
(b) a perimeter framing member engaging a peripheral edge of the panel, the perimeter framing member having two opposing surfaces for forming a pocket for receiving the peripheral edge of the panel; and
(c) an attachment member having a first bearing surface to be received in the groove in the first surface of the panel and a second bearing surface wedging against a surface of the perimeter framing member to align and maintain the panel in the pocket, wherein at least a portion of the attachment member is provided in a predetermined position between: (i) a surface (S) of the opposing surfaces of the pocket, and (ii) a surface of the panel;
wherein the second bearing surface is received in a groove located outside of the pocket when the panel is engaged with the attachment member; and
(d) a fastener for coupling with the attachment member outside of the pocket, wherein the fastener secures the portion of the attachment member in the predetermined position so that the following are provided:
(1) the first bearing surface is held in the groove in the first surface of the panel,
(2) the second bearing surface and a portion (P) of the perimeter framing member outside of the pocket are held together, and
(3) each of the first and second bearing surfaces contributes to inhibiting the panel from disengaging from the pocket.
28. A method of providing a wall system, comprising:
providing a panel having a predetermined groove in a surface thereof, and a peripheral edge;
inserting the peripheral edge in a pocket formed by two opposing surfaces of a framing member for the wall system;
securing the panel in the pocket using an attachment member having a first bearing surface and a second bearing surface;
the securing step including the substeps of:
(a) inserting the first bearing surface in the predetermined groove, the predetermined groove provided prior to insertion of the first bearing surface in the pocket; and
(b) coupling the second bearing surface with a portion of the framing member outside of the pocket;
wherein each of the first and second bearing surfaces contribute to inhibiting the panel from disengaging from the pocket.
29. The method of claim 28, wherein the step of securing includes a step of fastening the attachment member to the framing member with a fastener, wherein the fastener secures the attachment member in a predetermined position so that:
(a) there is a first coupling between the first bearing surface and the predetermined groove,
(b) there is a second coupling between the second bearing surface and a portion a portion of the framing member outside of the pocket, and
(c) at least a portion of the attachment member is operably rigid, and extends from the first bearing surface to the second bearing surface, each of the first and second couplings and the rigidity contributes to inhibiting the panel from disengaging from the pocket.
30. The method of claim 28, wherein the attachment member includes an operably non-deformable extent extending from the predetermined groove to a portion outside of the pocket, further including applying a persistent force applied to the extent from outside of the pocket for maintaining the first bearing surface in the predetermined groove;
wherein the force is in a direction operably traverse to a direction of the panel extending out of the pocket.
31. The method of claim 28, further including coupling a fastener to the attachment member and the framing member, the fastener being effective for pressing the second bearing surface against a portion (P) of the framing member outside of the pocket.
32. The method of claim 28, further including a step of inducing by the attachment member, a substantially greater total force for pressing the panel against one of the two opposing surfaces of the pocket, than a total force the attachment member induces against the other of the two opposing surfaces of the pocket. Description
The present application is a divisional of U.S. patent application Ser. No. 09/886,297, filed Jun. 20, 2001, now U.S. Pat. No. 7,272,913 to Mitchell, entitled “METHOD AND APPARATUS FOR ERECTING WALL PANELS”, which is a continuation of U.S. patent application Ser. No. 09/334,124, filed Jun. 15, 1999, to Mitchell of the same title, now U.S. Pat. No. 6,330,772, which is a continuation application of U.S. patent application Ser. No. 08/989,748, filed Dec. 12, 1997, to Mitchell, et al., now U.S. Pat. No. 5,916,100, which are all incorporated herein by this reference.
The first aspect of the present invention is directed to retarding the passage of terrestrial fluids through the joint between adjoining upper and lower wall panels. FIG. 1 depicts four adjacent wall panel mounting assemblies 50 a-d and the attached vertically oriented wall panels 54 a-d according to the first aspect of the present invention. Each wall panel mounting assembly 50 a-d includes a number of perimeter framing members 58 a-d, 62 a-d, 66 a-d and 70 a-d engaging each edge of the wall panels 54 a-d. Lower perimeter framing members 58 engage upper perimeter framing members 66, and perimeter framing members 62 engage perimeter framing members 70. As can be seen from FIGS. 1A and 1D, the upper perimeter framing members 66 (e.g., 66 a and 66 b) are configured to interlock in a nested relationship with corresponding lower perimeter framing members 58 (e.g., 58 c and 58 d). Referring to FIG. 1A, at least one of the upper and lower perimeter framing members has a capillary break 74 (FIGS. 1C and 2 as well), and a plurality of drainage holes 78 a-c in communication with a gutter 83 (FIG. 2 as well), defined by the lower perimeter framing member in the present embodiment.
The wall panels 54 can be composed of a variety of materials, including wood, plastics, metal, ceramics, masonry, and composites thereof. A preferred composite wall panel 54 is metal- or plastic-faced with a wood, metal, or plastic core. A more preferred wall panel 54 is a composite of metal and plastics sold under the trademark “ALUCOBOND”.
Referring to FIGS. 1C, 2 and 3, the upper and lower perimeter framing members 66 and 58 define a recess 82. The capillary break 74 extends downwardly from the upper perimeter framing member 66 to divide the recess 82 into a circulating chamber 86 and an inlet 90. The capillary break 74 is located nearer the wall panel 54 than the drainage holes 78 to block or impede the flow of droplets 94 (FIG. 3) entrained in the airstream 98 into the drainage holes 78.
FIG. 3 depicts the operation of the capillary break 74 and circulating chamber 86 during a storm. The airstream or wind 98 forces droplets of water 94 against the wall panels 54 (e.g., 54 b and 54 d). A film 102 of water forms on, e.g., the exterior surfaces of the wall. The wind pressure forces entrained droplets of water 94 and the film 102 into the inlet 90 between the wall panels 54 b and 54 d. The capillary break 74, which runs continuously along the length of each upper perimeter framing member 66 (e.g., 66 b in FIG. 3), decreases the cross-sectional area of air flow and therefore increases the velocity of the droplets 94. As the entrained droplets 94 enter the circulating chamber 86, the cross-sectional area of flow increases and therefore the velocity of the droplets 94 decreases forming a vortex 106. As a result, the droplets 94 have insufficient velocity to remain entrained in the air and the droplets collect in the film 102 on the lower surface 110 of the recess 82.
The degree of vortexing of the airstream depends, of course, on the increase in the cross-sectional area of flow as the airstream flows past the capillary break 74 and into the circulating chamber 86. If one were to define the space between the free end 124 (FIG. 2) of the capillary break and the opposing wall (i.e., lower surface 110) of the recess 82 as having a first vertical cross-sectional area, and the space between the vertically spaced apart opposing walls of the circulating chamber 86 (i.e., the distance “Hv”, FIG. 2) as having a second vertical cross-sectional area, the second vertical cross sectional area is preferably at least about 125% of the first vertical cross sectional area and more preferably at least about 150% of the first vertical cross sectional area.
FIG. 5 depicts a third embodiment of a wall panel mounting assembly according to the first aspect of the present invention. In this third embodiment, drainage holes 200 are located above the free end 124 of the capillary break 78 with an inclined surface 212 extending from the drainage holes 200 to a point below the capillary break 208. The inclined surface 212 facilitates removal of fluids from the recess 82 and thereby inhibits build-up of fluids in a corner of the recess 82 (i.e., a corner of the chamber 86).
FIGS. 6A and 6B depict a fourth embodiment of a wall panel attachment system according to the second aspect of the present invention (this second aspect briefly described in the Summary of the Invention section hereinabove). The system uses a flexible sheet interlock 250 (FIG. 6B) to seal inline adjacent perimeter framing members (e.g., perimeter framing members 258 a and 258 b, which may correspond to one of the pairs of lower perimeter framing members 58 a,b or 58 c,d of FIGS. 1, 1A and 1C). At the joint or gap 284 between the perimeter framing members 258 a and 258 b of adjacent wall panels 54 a,b (or 54 c,d), a flexible sheet interlock 250 inhibits fluid migration along the joint defined by the adjacent ends 254 a,b of the adjacent gutter segments (e.g., 83 a,b in FIG. 6B) of the perimeter framing members 258 a and 258 b. The flexible sheet interlock 250 realizes this result by retaining fluids in the adjacent gutter segments 83 a,b. Accordingly, the interface (e.g., 260, FIG. 7) between the flexible sheet interlock 250 and the gutter interior surfaces of the gutter walls 268 a,b,c is substantially impervious to fluid migration. As can be seen from FIG. 6B, the flexible sheet interlock 250 has sufficient flexibility to conform to the “U”-shaped contour of the gutter segments 83 a and 83 b. Referring to FIGS. 6A, 6B, and FIG. 7, surface 251 of the flexible sheet interlock 250 between the adjacent ends 254 a,b is shown, and in particular, in FIG. 7, this surface is shown in both an extended and bowed configuration. The interface 260 (FIG. 7) can include an adhesive 264 between the flexible sheet interlock 250 and each of the three gutter walls 268 a,b,c to retain the interlock 250 in position. Although the flexible sheet interlock 250 itself may possess adhesive properties, an adhesive, preferably having sealing properties, has been found to assist the formation and maintenance of an integral seal between the interlock 250 and the gutter interior surfaces of the gutter walls 268 a,b,c. The most preferred adhesive is a high performance compressed joint sealant that can “set up” or harden and bond to the gutter walls 268 a,b,c and the interlock. Examples of such sealants include silicone, urethane, and epoxy. Because the interlock 250 itself absorbs all of the thermal movement of the wall panels, there is no requirement for the adhesive 264 to stay resilient and move. The end result is a more economical system for sealing the gap 284 between the gutter segments 83 a,b of adjacent perimeter framing members (e.g., 258 a, b) that has a useful life equal to that of the exterior wall panel system.
(i) there is a corresponding semi-cylindrical grove or notch 285 within a surface of the corresponding adjacent panel 54 for mating with (or more generally, engaging) a corresponding surface portion 290 a (also referred to as a “bearing surface”) of the attachment member 290, and (ii) there is a corresponding semi-cylindrical groove (or more generally, “grooved member”) 291 in each of the first of the opposing surfaces 286 for mating with (or generally, engaging) a corresponding surface portion 290 b (also referred to as a “bearing surface”) of the attachment member 290. In a third method for installing the flexible sheet interlock 250 shown in FIGS. 12-13, the inner surface 299 of the gutter segment 83 a includes a lip 302 extending inwardly to protect the edges of the interlock 250 during installation of the upper perimeter framing member 266. The width of the lip “HL” (FIG. 12) is preferably at least the same as the thickness “TI” (FIG. 13) of the interlock 250.
The installation method will now be explained with reference to FIGS. 8-9 and 14-15. In a first step, the wall panel system 500 a (FIG. 15) is attached to the wall support members. In a second step, the adhesive 264 (FIG. 7) is applied to either or both of a flexible sheet interlock 250 and adjoining interior gutter surfaces of walls 268 a-c (FIG. 14), and the flexible sheet interlock 250 is engaged with each end 254 a,b (FIGS. 6B and 14) of the wall panel system 500 a. In a third step, the wall panel systems 500 b,c are attached to the wall support members, wherein the corresponding flexible sheet interlocks 250 are attached to the ends of each system's gutter segment (e.g., 83 a or 83 b) as described above. In a fourth step, the protruding end 504 of the interlock 250 is folded away from the edge of the wall panel system 500 a as shown in FIG. 14, and the wall panel system 500 d is attached to the wall support members. A flexible sheet interlock 250 is then attached to the gutter segment (e.g., 83 a or 83 b) at the end of the wall panel system 500 d as described hereinabove. The above steps are repeated to install the remaining wall panel systems 500 e-500 f. Referring to FIGS. 16-21, a fourth embodiment according to a third aspect of the present invention is illustrated. The third aspect of the invention is used to attach embodiments of the wall panels to an alternative embodiment of the perimeter framing members denoted by the label 304 to distinguish it from the perimeter framing members described hereinabove. The wall panel assembly 300 (e.g., FIG. 19) includes a perimeter framing member 304, a wedge-shaped member 306, and an attachment member 308 (which secures a wall panel within a pocket 289, but differently from attachment member 290, FIG. 10, and which is preferably a rigid or semi-rigid material such as metal). The attachment member 308 has an L-shaped member 312 that engages a grooved member 316 in the perimeter framing member 304. The attachment member 308 has a cylindrically-shaped bearing surface 320 that is received in a groove 324 in a wall panel 54 (also identified as a panel member 54 herein) substantially along the length of the side of the panel member 54. One end 336 of the wedge-shaped member 306 engages a step 332 in the perimeter framing member 304 and the other end 340 of the wedge-shaped member 306 engages a step 344 in the attachment member 308. The wedge-shaped member 306 is suitably sized to cause the bearing surface 320 of the attachment member 308 to be forced against the groove 324 in the panel member, thereby holding the panel member in position. The bearing surface 320 can have any number of desired shapes, including v-shaped, star-shaped, and the like.
The steps to assemble the panel member assembly 300 are illustrated in FIG. 16. In the first step illustrated by FIG. 16, the panel member 54 is positioned in the pocket 289 of the perimeter framing member 304. In FIG. 17, the L-shaped member 312 (which is part of the attachment member 308) is engaged with the grooved member 316 (FIG. 18) of the perimeter framing member 304, and the bearing surface 320 is engaged with the groove in the panel member 54. In FIGS. 18-19, the lower end 340 of the wedge-shaped member 306 is engaged with the step 344 of the attachment member, and the upper end 336 of the wedge-shaped member 306 is then forcibly engaged with the step 332 in the perimeter framing member 304. Note that as shown in FIG. 18, for an axis 351:
(i) having a first position 352 a that is offset from the surface 353 of the panel member 54 on a side also having the surface 354 of the pocket 289, and (ii) having a second position 352 b that is offset from the surface 353 on a side not having the surface 354,
The perimeter framing members 304 a,b (FIG. 22) are in the interlocked position for mounting the panels on a support surface. Note that FIG. 22 shows the parallel surfaces 412 a and 412 b of the peripheral edges of the panels 54 n and 54 p, wherein each of the surfaces 412 a and 412 b engage an interior surface of a corresponding pocket 289 of one of the perimeter framing members 304 a and 304 b (such perimeter framing members also referred to as panel receiving members hereinbelow). Moreover, the panels 54 n and 54 p are spaced apart from one another by a channel or gap 424, wherein the channel or gap is bounded by facing sides, each side being provided by a different one of first and second perimeter framing members 304 a and 304 b, and each side being an exterior surface of one of the pockets 289 receiving a corresponding peripheral edge of one of the panels 54 n and 54 p. While various embodiments have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the scope of these inventions, as set forth in the following claims.
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