WO2000031357A1 - Composite joinery - Google Patents
Composite joinery Download PDFInfo
- Publication number
- WO2000031357A1 WO2000031357A1 PCT/US1999/022810 US9922810W WO0031357A1 WO 2000031357 A1 WO2000031357 A1 WO 2000031357A1 US 9922810 W US9922810 W US 9922810W WO 0031357 A1 WO0031357 A1 WO 0031357A1
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- WO
- WIPO (PCT)
- Prior art keywords
- panel
- reveal
- building
- forming
- building wall
- Prior art date
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
Definitions
- the present invention relates generally to joint arrangements and, more particularly, to composite, external panel joints for buildings.
- Each panel typically includes one or more liners that encase a homogenous core, such as a foam core. It is also known to provide each panel with one or more "male” or “female” connecting portions, each configured to accommodate respective “female” or “male” connecting portions of the other panel .
- an internal gutter may be included in order to accommodate liquid that has bypassed the joint.
- One way to drain the liquid is via the provision of vertical channels between horizontally adjacent panels.
- Such gutters also often typically serve as effective media for equalizing pressure within the horizontal joint in question.
- U.S. Patent No. 5,749,282, to Brow et al . discloses a conventional horizontal joint having these features.
- the present invention contemplates, in accordance with at least one presently preferred embodiment, an arrangement in which at least one aperture is provided over a predetermined horizontal extent of an internal gutter of a horizontal joint.
- any liquid collected in the internal gutter may drain outwardly through the aperture (s) in the gutter, rather than, or in addition to, being fed to vertical channels.
- the present invention also contemplates, in accordance with at least one presently preferred embodiment, a reveal (i.e., an inward recess into at least one of the upper and lower panels) that is considerably deeper than the norm, conceivably two or three times as deep.
- a reveal i.e., an inward recess into at least one of the upper and lower panels
- the advantages include eased bending in corner panels and the fact that unsightly repairs can be concealed in the back of the reveal.
- a sloped drainage shelf may be provided as part of the reveal, in order to assist drainage.
- another concept contemplated by at least one presently preferred embodiment of the present invention is the customization of horizontal joints to have any of a variety of reveal sizes or types.
- the reveal can be changed in size so that, for example, reveal sizes from 1/8" to 2" are attainable in 1/4" increments.
- Another concept contemplated by at least one presently preferred embodiment of the present invention is the selective, customizable juxtaposition of insulative panels, such as those including structural foam, with simple profile panels in a desired predetermined arrangement .
- Unique connective media are preferably provided for this purpose.
- At least one presently preferred embodiment of the present invention broadly contemplates a horizontal joint between upper and lower building panels, wherein: the lower panel comprises at least one connector comprising at least one of: at least one male connector and at least one female connector; the upper panel comprises at least one connector comprising at least one of: at least one male connector and at least one female connector; at least one connector of the upper panel being connected with at least one connector of the lower panel to form an outer joint; an arrangement for diverting liquid; the liquid diverting arrangement comprising a gutter; the gutter having first and second ends; the liquid diverting arrangement further comprising at least one aperture disposed between the first and second ends of the gutter.
- At least one presently preferred embodiment of the present invention broadly contemplates a building wall comprising: an upper building panel and a lower building panel; the lower panel comprises at least one connector comprising at least one of: at least one male connector and at least one female connector; the upper panel comprises at least one connector comprising at least one of: at least one male connector and at least one female connector; at least one connector of the upper panel being connected with at least one connector of the lower panel to form an outer joint; an arrangement for diverting liquid; the liquid diverting arrangement comprising a gutter; the gutter having first and second ends; the liquid diverting arrangement further comprising at least one aperture disposed between the first and second ends of the gutter.
- At least one presently preferred embodiment of the present invention broadly contemplates joint between two building panels, comprising a reveal having a depth that is no less than about 0.75 inch.
- At least one presently preferred embodiment of the present invention broadly contemplates a method of forming at least two building panels, the method comprising the steps of: providing apparatus for forming building panels; forming a first panel with the apparatus; forming a second panel with the apparatus; the forming of the first panel comprising the formation of at least a portion of a first reveal; and the forming of the second panel comprising the formation of at least a portion of a second reveal; wherein the first and second reveals comprise different dimensions.
- At least one presently preferred embodiment of the present invention broadly contemplates apparatus for forming at least two building panels, the apparatus comprising: an arrangement for forming first and second panels; the panel forming arrangement comprising an arrangement for forming at least a portion of a first reveal in the first panel and at least a portion of a second reveal in the second panel; the reveal forming arrangement comprising an arrangement for imparting different dimensions to the first and second reveals .
- At least one presently preferred embodiment of the present invention broadly contemplates a method of forming a building panel, the method comprising the steps of: forming a first portion of a reveal in the building panel; forming a second portion of the reveal at a preselectably variable distance with respect to the first portion; and thereafter registering the first portion of the reveal.
- At least one presently preferred embodiment of the present invention broadly contemplates apparatus for forming a building panel, the apparatus comprising: an arrangement for forming a first portion of a reveal in the building panel; an arrangement forming a second portion of the reveal at a preselectably variable distance with respect to the first portion; and an arrangement for registering the first portion of the reveal .
- At least one presently preferred embodiment of the present invention broadly contemplates method of customizably assembling a building wall, the method comprising the steps of : providing at least one panel having a first thickness dimension; providing at least one panel having a second thickness dimension, the second dimension being different from the first dimension; and effecting at least one connection between a panel having the first thickness dimension and a panel having the second thickness dimension; wherein at least one of: a panel having the first thickness dimension and a panel having the second thickness dimension comprises an arrangement for interchangeably connecting with a panel having the first thickness dimension and a panel having the second thickness dimension.
- At least one presently preferred embodiment of the present invention broadly contemplates a kit for customizably assembling a building wall, the kit comprising: at least one panel having a first thickness dimension; and at least one panel having a second thickness dimension, the second dimension being different from the first dimension; wherein at least one of: a panel having the first thickness dimension and a panel having the second thickness dimension comprises an arrangement for interchangeably connecting with a panel having the first thickness dimension and a panel having the second thickness dimension.
- At least one presently preferred embodiment of the present invention broadly contemplates a method of customizably assembling a building wall, the method comprising the steps of: providing at least one panel of a first type; providing at least one panel of a second type; effecting at least one connection between a panel of the first type and a panel of the second type; the at least one panel of the first type comprising a structural building wall panel; the at least one panel of the second type comprising a decorative profile panel; at least one of: the building wall panel and the decorative profile panel comprising an arrangement for interchangeably connecting with a panel of the first type and a panel of the second type.
- At least one presently preferred embodiment of the present invention broadly contemplates a kit for customizably assembling a building wall, the kit comprising: at least one panel of a first type; at least one panel of a second type; the at least one panel of the first type comprising a structural building wall panel; the at least one panel of the second type comprising a decorative profile panel; at least one of: the building wall panel and the decorative profile panel comprising an arrangement for interchangeably connecting with a panel of the first type and a panel of the second type.
- Figure 1 is a fragmentary isometric view illustrating an exterior wall structure in a conventional horizontal panel application
- Figure 2 is a broken cross-sectional view, taken along the line 2-2 of Figure 1, illustrating a conventional insulated building panel;
- Figure 3 is a cross-sectional view, taken along the line 3-3 of Figure 1, illustrating a conventional horizontal joint.
- Figure 4 is a cross-sectional view illustrating an insulated building panel according to the present invention.
- Figure 4a is a perspective, isolated view of a face sheet and gutter having one type of aperture disposed therein;
- Figure 4b is substantially the same view as Figure 4a but illustrating another type of aperture
- Figure 4c is substantially the same view as
- Figure 4a but illustrating yet another type of aperture
- Figure 4d is substantially the same view of Figure 3, but illustrating an aperture arrangement through the structural foam core
- Figure 5 is substantially the same view as Figure 4, but illustrating a "mid-hook" face sheet attachment ;
- Figure 6 is substantially the same view as Figure 4, but illustrating a narrower reveal width
- Figure 7 is substantially the same view as Figures 4 and 7, but showing a greater reveal width
- Figure 8 is substantially the same view as Figure 4, but illustrating an upper panel of greater depth than the lower panel ;
- Figure 9 is substantially the same view as Figure 4, but illustrating a lower panel of greater depth than the upper panel ;
- Figure 10 is substantially the same view as Figure 4, but illustrating upper and lower panels of greater depth than those shown in Figure 4 ;
- Figure 11 is substantially the same view as
- Figure 11A illustrates a conventional registration block arrangement used in the formation of building panels
- Figure 11B illustrates a registration block arrangement in accordance with an embodiment of the present invention
- Figure 12 illustrates a building wall portion that includes both foam panels and profiled sheet metal panels
- Figure 13 is a close-up cross-sectional view taken from Figure 12, and illustrating a connection between a profiled panel and a foam panel;
- Figure 14 is a close-up cross-sectional view taken from Figure 12, and illustrating a connection between two profiled panels.
- Figure 15 is a close-up cross-sectional view taken from Figure 12, and illustrating a connection between two foam panels.
- FIGS. 1-3 are taken from U.S. Patent No. 5,749,282 (Brow et al . ) for the purpose of illustrating conventional horizontal joinery, and associated components, having aspects that might be utilized in accordance with at least one presently preferred embodiment of the present invention.
- the same patent is fully incorporated by reference into this specification, in order that further conventional details forming the background and/or environment of at least one presently preferred embodiment of the present invention may be relied upon as needed.
- FIG. 1 there is illustrated an exterior wall structure 10 supported on a structural framework including vertical columns 12.
- the wall structure 10 is assembled from individual panels 14 having adjacent panel ends 16, 18 forming a vertical joint 20 and being connected along the lower and upper side edges 22, 24 to form horizontal wall joint 26.
- the insulated building panel 14 comprises inner and outer facing sheets 28, 30 and a structural foam core 32 filling the interior space of the building panel 14 and adhesively connecting the facing sheets 28, 30 to provide a structural panel.
- the inner and outer facing sheets 28, 30 provide inner and outer male connectors or tongues 34, 36.
- the inner and outer facing sheets 28, 30 provide inner and outer female connectors 38, 40 adapted to receive the tongues 34, 36 of a subjacent building panel.
- the inner and outer female connectors 38, 40 each receive a bead 42, 44 of sealant, such as a non-hardening butyl sealant.
- the beads 42, 44 of sealant are adapted to be penetrated by the tongues 34, 36 of a subjacent panel to form inner and outer seals as shown in Figure 3.
- gutter means 45 is provided at the upper edge 22 of the building panel 14 and intermediate of the inner and outer tongues 34, 36.
- the gutter means extends substantially entirely along the full length of the building panel 14.
- the gutter means serves to eliminate liquids bypassing the outer joint formed between the female connector 40 and the tongue of 36 of a subjacent building panels.
- the gutter means 45 has a generally U-shaped transverse profile including upstanding sides 46, 48 and a web of 50 connecting the sides 46, 48.
- the side 48 of the gutter means 45 also constitutes a portion of the tongue 36. Therefore, the gutter means 45 is formed, in part, by the outer male connector tongue 36.
- FIG. 3 there is illustrated a horizontal joint 26 between upper and lower panels 14A, 14B. Comparing Figures 2 and 3, it will be observed that the location of the upper edge 22 may be varied, as shown at 22' and 22", and thus the width of the horizontal joint 26 may be varied as shown at 26' and 26".
- the lower building panel 14 is secured to the column 12 by a clip 56 and a fastener 58.
- the clip includes a downturned central flange at 60 penetrating the foam core 32B and engaging the inner facing sheet 28B and a pair of inclined flanges 62, only one visible in Figure 3, penetrating the foam core 32B and extending into the tongue 34B.
- the clip 56 also has a main flange portion 64 which overlies the upstanding side 46 of the outer facing sheet 30B.
- the fastener 58 extends through the main flange portion 64, the upstanding side 46, the foam core 32B, the inner facing sheets 28B and into the vertical column 12. In this manner, both the inner and outer facing sheets 28B, 30B of the panel 14B are secured to the vertical column.
- Figure 4 is a cross-sectional view illustrating an insulated building panel according to at least one presently preferred embodiment of the present invention.
- thermal break 190 reveal 192
- aperture (s) or weep hole [s]
- sloped shelf 196 and edge-hook connection 198.
- Thermal break 190 indicated with dotted lines at upper panel 114A, merely constitutes a gap between outer face sheet 130A (often termed simply a "face sheet”) and inner face sheet 128A (often termed a "liner” or “liner sheet”) , wherein a portion of the foam core 132A is exposed.
- a similar thermal break exists on lower panel 114B, not numbered but indicated with dotted lines between outer face sheet 130B and inner face sheet 128B.
- foam core 132A/132B essentially represents only one type of core material that can be utilized in a composite building panel (or structural panel) .
- core material such as a conventional honeycomb core structure.
- Indicated at 192 is what is known in the art as a reveal, or, in the context of a building wall assembly, an indentation that is recessed into the wall assembly.
- reveal 192 is defined between upper panel 114A and lower panel 114B.
- a reveal provides an enhanced visual effect on the outer side of a building wall assembly.
- reveals tend to be shallow, that is, of limited dimension in a direction defined orthogonally between the outer side of the wall assembly and the inner side.
- “depth” or “thickness” may be defined as that dimension oriented horizontally with respect to Figure 4, while the dimension perpendicular thereto in Figure 4, oriented vertically, may be defined as "width” .
- the present invention in accordance with at least one presently preferred embodiment, broadly contemplates a reveal 192 that is considerably deeper than the norm. Surprisingly, it has been found that such a reveal provides an enhanced visual effect from the outside and, further, that it is easier to fabricate and install corner panels, and connections therebetween, having such a reveal . Additionally, any repairs that are located within the reveal are essentially hidden to passersby because of the depth of the reveal. Such repairs might include, but are not limited to, those that are undertaken when forming a corner joint, particularly, when, subsequent to cutting a V-notch in the panels to be used at a corner and bending the panels, plate or sheet material is provided at the seam where the V-notch was cut .
- the depth of the reveal is indicated as the dimension x in Figure 4. In accordance with a presently preferred embodiment of the present invention, this dimension will be no less than about 0.75 inch. In the illustrated example, dimension x is 1.25 inches, while the depth of both panels 114A and 114B is 2 inches. Surprising and unexpected advantages, as described above, have been encountered with deep reveals. Further, the present invention broadly contemplates reveals having dimensions that are even greater than 1.25 inches, as deep as is practicable in view of the physical requirements inherent to the wall assembly in question.
- a sloped shelf 196 may preferably be provided within reveal 192. In accordance with at least one presently preferred embodiment of the present invention, the shelf 196 will be sloped at about three degrees. Conventionally, slopes of five degrees have been encountered.
- arrow 194 illustrates the presence of one or more apertures through face sheet 13 OB, and at the bottom of gutter 145, through which liquid present in the gutter
- One or more such apertures may preferably be distributed throughout the length (i.e. in a direction perpendicular to the plane of the drawing) of gutter 145. For example, one such aperture may be present about every 12 inches along the length of gutter 145.
- the location and distribution of the aperture (s) will be chosen in such a manner as to drain liquid from the gutter, and also to equalize pressure within the gutter, most efficiently and effectively.
- Figures 4a-4c illustrate, in isolated perspective view, a lower panel face sheet 130B, where this forms gutter 145, with different types of apertures that might be utilized in accordance with at least one presently preferred embodiment of the present invention.
- Figure 4a illustrates a bottom aperture 194a, which may be disposed in a lowermost or bottom portion of gutter 145.
- Figure 4b illustrates an "edge notch" aperture 194b, which may be disposed in a portion of gutter 145 that is away from an end corner 145C of gutter 145.
- Figure 4c illustrates a "corner notch" aperture
- apertures illustrated in Figures 4a-4c are provided as examples only, and are not intended in any way to limit the scope of the present invention.
- the aperture or apertures in question is/are disposed intermediately with respect to the opposing ends of the gutter, in contrast or in addition to arrangements in which the gutters open at their ends to vertical discharge channels, as described in the patent to Brow et al .
- the present invention also contemplates, in accordance with at least one presently preferred embodiment, an arrangement in which the one or more apertures being used are not disposed to direct liquid flow from what are essentially lowermost portions of gutter 145, as illustrated in Figures 4a-4c, but are disposed at somewhat higher points of the gutter wall that faces outwardly.
- liquid will accumulate within the gutter and will discharge from the aperture (s) once the liquid level within the gutter matches the level of the aperture (s) .
- the present invention contemplates such an arrangement particularly in conjunction with the use of vertical discharge channels, as discussed in the patent to Brow et al .
- the aperture (s) presently contemplated can serve the purpose of overflow drainage, in the event that the normal drainage through the gutter end(s) to the vertical discharge channels is backed up or inhibited for any reason.
- a deep reveal 192 may be utilized in conjunction with the aperture (s) 194 just described.
- the reveal 192 may preferably be defined partly by a sloped shelf 196.
- a sloped shelf will preferably assist considerably in diverting any liquid emanating from apertures 194 out of the reveal 192.
- the sloped shelf 196 also serves to divert away liquid from external sources, such as rain that is blown into the reveal 192 by the wind that enters reveal 192 by washing down the external face of the building wall assembly.
- the shallow slope discussed heretofore preferably of about three degrees, has been found to be quite adequate for affording drainage away from the reveal 192.
- reveal 192 will have a predetermined width y. A manner of customizing this width will be discussed further below. In the embodiment illustrated in Figure 4, if it is assumed that the overall depth of the panel structure is about 2 inches, then dimension y, the width of the reveal 192, is illustrated as being 1/2 inch, which is recognized throughout the industry as a standard width.
- aperture (s) 194d may proceed from gutter means 45B, through foam core 32B, and may exit through an opening in face sheet 3 OB.
- the present invention contemplates not only the use of one or more apertures in conjunction with a deep reveal that permits immediate egress of liquid from an internal gutter arrangement to the outside, but also in conjunction with a structural panel containing a foam or other core, such as the panel 14B shown in Figure 4B, wherein aperture (s) 194d may actually tunnel through the foam or other core in a suitable manner in order to facilitate the egress of liquid from an internal gutter arrangement.
- a structural panel containing a foam or other core such as the panel 14B shown in Figure 4B
- aperture (s) 194d may actually tunnel through the foam or other core in a suitable manner in order to facilitate the egress of liquid from an internal gutter arrangement.
- aperture (s) could be provided instead of or in addition to the types of vertical discharge channels that are described in the patent to Brow et al .
- FIG. 198 Indicated at 198 is an edge-hook, or terminal portion, of outer face sheet 130B. It has been found that forming a face sheet in such a manner provides for a sounder connection with upper panel 114A than might otherwise be encountered.
- Figure 5 illustrates a "mid-hook" 199 in place of the edge-hook 198 of Figure 4.
- Mid-hook 199, in Figure 5 is preferably formed as a crimped, intermediate portion of face sheet 130B, configured for extending upwardly into a corresponding pocket in upper panel 114A.
- Figures 6 and 7 represent substantially similar views as Figure 4, but illustrate, respectively, a narrower reveal width and a greater reveal width. Particularly, if it is assumed that the overall depth of the panel structure is about 2 inches in each case, then dimension y, the width of the reveal 192, is illustrated as being 1/8 inch in Figure 6 and 2 inches in Figure 7. As will be described further below, the present invention contemplates, in accordance with at least one presently preferred embodiment, the possibility of customizing dimension y in a unique manner. The disclosure now turns to a discussion of a particularly versatile application afforded by at least one presently preferred embodiment of the present invention. In Figures 8-10, components that are substantially analogous to components in Figures 1-3 have been so indicated by advancing the reference numerals by 200.
- Figure 8 illustrates an example in which upper panel 214A has a notably greater overall depth (or thickness) z than the overall depth (or thickness) a of lower panel 214B.
- dimension a is equal to about 2 inches while dimension z is equal to about 2.75 inches.
- dimension x is still equal to about 1.25 inches.
- Figure 9 illustrates an example in which upper panel 214A has a notably smaller overall depth z than the overall depth a of lower panel 214B.
- dimension a is equal to about 2.75 inches while dimension z is equal to about 2 inches.
- dimension x, or the greatest depth of the reveal is equal to about 2 inches.
- the proportion represented by the greatest reveal depth x with respect to the depth a of the lower panel has thus increased to about 8/11, or about 0.727.
- Figure 10 illustrates an example in which upper panel 214A has the same, larger overall depth z as the overall depth a of lower panel 214B.
- dimension a is equal to about 2.75 inches while dimension z is also equal to about 2.75 inches.
- Dimension x, or the greatest depth of the reveal is again equal to about 2 inches, and the proportion represented by the greatest reveal depth x with respect to the depth a of the lower panel is again 8/11, or .727.
- Figures 8-10 illustrate a measure of versatility, in assembling wall assemblies, afforded by at least one presently preferred embodiment of the present invention. In each case, it is possible to maintain a significantly deep reveal, with the attendant advantages described heretofore.
- an upper bent portion 298 of lower outer face sheet 230B may preferably be so configured and designed as to mate adequately with a corresponding recessed portion of upper outer face sheet 230A.
- the bent portion 298 is in the form of a "J-hook", but could also be configured as a "mid- hook” as shown in Figure 11.
- the present invention broadly contemplates, in accordance with at least one presently preferred embodiment, the facilitated interchangeable assembly of various upper panels 214A and lower panels 214B of differing depths, whereas conventionally this might have been difficult and cumbersome in view of differing and incompatible connection schemes.
- the "J-hook" 298 shown in Figures 8-10 could be realized in two discrete pieces, as opposed to the single piece shown. Thus, one smaller piece would be constituted only by the J-shaped portion. In this manner, the tight 180-degree bend illustrated in Figures 8-10 would be eliminated.
- the separate J-hook 298A could be formed from a lighter gauge material, such as stainless steel or aluminum.
- a separate J- hook might be desirable for other reasons, as determined by the dictates of the user.
- Figures 8-10 can be utilized in the context of vertically-oriented panels, as opposed to horizontally-oriented panels.
- Figures 8-10 can be interpreted as plan, rather than elevational, views and that the connection between panels 214A and 214B can be construed as a vertical joint, rather than a horizontal joint.
- aperture (s) 294 does not necessarily detract from the use of panels 214A and 214B in a vertical orientation, as they could conceivably assist in serving the purpose of pressure equalization, especially if internal gutter 245 does not lead to orthogonally oriented external channels at either of its ends .
- FIG. 11 illustrates an arrangement in which the width (i . e . , the dimension y shown in earlier drawings) of reveal 392 can be customized.
- an optional drip edge 396 is also shown.
- suitable tooling may be utilized to quickly and efficiently change over an appropriate forming apparatus, such as a roll- forming apparatus, from one configuration, in which one given reveal width is produced, to another configuration, in which another given reveal width is produced. It is believed that this type of versatile customization would be of great benefit to manufacturers who would wish to cater, at short notice, to the divergent requests of one or more customers as regards the width of a reveal .
- reveal widths from about 1/8" to greater than about 2" (such us up to about 6") are possible, such as in increments of about X A" .
- Figure 11A illustrates a conventional registration block (or side rail) arrangement typically utilized subsequent to the roll-forming of face sheets for building panels.
- registration blocks are used to hold face sheets in an accurate positional relationship prior to, and during, the application of an insulative material, such as foam, between the face sheets.
- block 402 may include, among other things, a first end face 404 and a second end face 406.
- first end face 404 is configured for engaging with that portion 405a of an inner face sheet 405 ( e . g. , similar to sheet 328B shown in Figure 11) that has been bent at one end of inner face sheet 328B.
- second end face 406 is configured for engaging with that portion 408a of an outer face sheet 408 ( e . g. , similar to sheet 330B shown in Figure 11) that forms the lower part of a reveal (such as reveal 392 shown in Figure 11) .
- an outer face sheet 408 e . g. , similar to sheet 330B shown in Figure 11
- a reveal such as reveal 392 shown in Figure 11
- the engagement of a registration block with face sheets takes place once the face sheets have already been roll-formed, or formed in some other manner, for the purpose of positioning and aligning the face sheets with respect to one another in preparation for the injection or insertion of the desired core material between the face sheets.
- the foam is typically injected into the cavity between the two face sheets (once registered via the registration block) , and the registration block typically assists in preventing the foam from inadvertently leaking from this cavity during the injection process.
- registration block 402 in connection with the conventional example shown in Figure 11A, provides registration at two significant points, namely the aforementioned "bend" portion 405a of an inner face sheet 405 and the lower "reveal" portion 408a of an outer face sheet 408.
- a disadvantage that has often been encountered with the type of registration block illustrated in Figure 11A is that essentially only one predetermined and fixed reveal width can be accommodated. Particularly, since that portion of the outer face sheet defining the lower limit of the reveal is used in registration, then only one reveal width, as defined by the formation of the same portion of the outer face sheet, can essentially only be introduced to the corresponding registration block. In the industry, it is well-known that such registration blocks are expensive items to purchase and install. Thus, the capacity for customizable formation with different reveal widths is severely hampered, as a different registration block is essentially required for each different reveal width that is introduced.
- Figure 11B illustrates a registration arrangement, according to at least one presently preferred embodiment of the present invention, that is configured to accept outer face sheets that result in different reveal widths.
- a registration block 452 may include a first face 454 and a second face 456.
- first face 454 will preferably be configured as to engage with that portion
- the second end face 456 is preferably configured for engaging not with a portion of an outer face sheet 458 ( e . g. , similar to sheet 330B shown in Figure 11) that forms the lower part of a reveal (such as reveal 392 shown in Figure 11) , but with a portion 458a of an outer face sheet 458 that forms a portion of the top of the reveal.
- registration block 452 provides registration at two significant points that are different from the significant points encountered by the registration block 402 shown in Figure 11A.
- the significant points are the aforementioned "bend" portion 455a of an inner face sheet 455 and the "upper" reveal portion 458a of an outer face sheet 458.
- inventive arrangement shown in Figure 11B can lend itself admirably to a forming apparatus in which a roll -forming unit and a foam injection unit (or a unit otherwise dedicated to the introduction of an insulative material) are included in the same assembly line, so that sheets that have been roll-formed can progress automatically to a registration block for the subsequent introduction of insulative material.
- a registration arrangement such as that shown in Figure 11B, it will be possible to change reveal widths quickly and efficiently, perhaps even on the fly.
- inventive arrangement shown in Figure 11B with its registration points at regions 455a and 458a of face sheets 455 and 458, respectively, also aids considerably in preventing the inadvertent escape of foam from the space formed between the face sheets 455 and 458, and in fact has been found to represent a marked improvement as such in comparison with conventional arrangements.
- Figure 12 illustrates a general wall assembly 500 having composite structural panels, such as foam panels, 501 along with decorative profile panels 503.
- decorative profile panels 503 are formed from sheet metal and may contain therewithin some form of insulation and, as shown, may also contain decorative or otherwise aesthetically significant features, such as the types of indentations shown in Figure 12.
- connection scheme Indicated at 513 is a first connection scheme, to be described and illustrated in more detail with respect to Figure 13.
- 514 indicates a second connection scheme, corresponding to Figure 14, whilst 515 indicates a third connection scheme, corresponding to Figure 15.
- these three types of connection schemes are of such a nature that they afford the easy and customizable interchanging and intermingling of structural panels 501 and profile panels 503.
- a profile panel 503 is connected atop a structural panel 501.
- structural panel 501 includes a structural foam core that is flanked by outer face sheet (or simply “face sheet”) 518 and inner face sheet (or “inner” or “liner sheet”) 519, respectively.
- face sheet or simply “face sheet”
- inner face sheet or “inner” or “liner sheet”
- reveal 522 may be defined between the upper, profile panel 503 and the lower, structural panel 501.
- a suitable attachment mechanism 524 such as a bolt, may be used to hold firmly a clip 526.
- This clip 526 may include legs 528 and 530, the former extending into the structural foam core 516 and the latter extending upwardly into a nook or bend formed in inner face sheet 519.
- a suitable sealant or sealing arrangement 532 may be provided between panels 503 and 501.
- Upper profile panel 503 itself preferably contains outer and inner facing (or face) sheets 534 and 536, respectively.
- outer face sheet 534 At the lower end of outer face sheet 534, there is preferably a bent terminal portion 535 that serves as a receptacle for the "J-hook" portion 520 of outer face sheet 518 of lower structural panel 501.
- a sheet of insulation 538 may preferably be provided within profile panel 503.
- a first profile panel 503a is connected atop a second profile panel 503b.
- Similar reference numerals, indicating similar components, have been retained from Figure 13, with the addition of “a” or “b” to indicate components in panels 503a and 503b, respectively.
- the outer face sheet 518b of lower panel 503b may include an intricately bent end portion
- a clip configured for mating with the lower bent portion 535 of the outer face sheet 518a of upper panel 503a.
- a suitable attachment device such as a bolt, 543, may preferably be configured for accommodating part of bent end portion
- 540 may preferably have a splayed upper end, as shown, to accommodate a bent upper portion of inner face sheet 536b of lower panel 503b.
- a suitable sealant or sealing arrangement 532 ' is preferably provided.
- a clip 546 may preferably be utilized with attachment devices (such as bolts) 548 and 550 that extend into and/or through insulation sheet 538.
- An adapter clip 552, extending from the attachment point of attachment device 550 with clip 546, may preferably be configured to extend into the recess created by lower bent portion 535 of structural panel 501.
- profile panels have tended to be formed in rather singular manner at their connectable ends. It will thus be appreciated that, in accordance with at least one presently preferred embodiment of the present invention, such panels will preferably undergo at their ends such artificial formation as to be fully integrable with either another profile panel or a structural panel .
- a profile panel is adaptively configured so as to be able to mate with a structural building panel in such a manner as to mimic essentially the same physical characteristics, and associated advantages, normally found in a connection between two structural building panels.
- the inner face sheets in question will preferably be realized in such a manner as to result in the establishment of a consistent barrier, with consistent sealing, against vapor pressure, air infiltration and water infiltration.
- the present invention contemplates the inclusion of such sheets in a manner that essentially mimics the manner in which they are realized in structural panels.
- the upper and lower panels in each case, be they structural or profile panels exhibit similar physical and operational characteristics.
- the liner sheets of the upper and lower panels will exhibit coplanarity as in an interconnection between structural panels (see, for example, Figure 4) .
- a factory-installed seal (e . g. , such as indicated at 532 and 532') is normally supplemented, in the context of adjacent structural panels, by a field-installed seal.
- the field-installed seal normally abuts the liner sheets on the building side of the wall assembly, and will normally migrate into cavities between the upper and lower panels so as to "meet" the factory-installed seal.
- Such a sealing arrangement provides very favorable protection against air, vapor and water infiltration.
- a profile panel will mimic several characteristics of a structural panel, a similar advantage will be encountered here.
- material from a field-installed seal will preferably migrate into a cavity 533 (as shown in each of Figures 13-15) between upper and lower panels, resulting in the same advantages as just described.
- Yet another advantage can be found in that essentially the same type of formation tooling, such as roll-form tooling, can be utilized to form the face or liner sheets of structural panels and profile panels alike .
- any and all of the building panels, and interconnections, illustrated and described herein may be utilized either in a horizontal configuration or in a vertical configuration.
- the structures and components described and illustrated herein in connection with at least one presently preferred embodiment of the present invention are applicable not only to the context of horizontal panels connected by horizontal joints but also to the context of vertical panels connected by vertical joints.
- a deep reveal offers several unique features.
- the depth of reveal allows it to perform as a pressure equalized pocket, possibly in addition to an internal pressure equalized pocket (such as may be afforded by an internally disposed gutter) , while allowing venting of the panel, such as along the entire length of the panel .
- the depth also creates a reveal with a bolder aesthetic appearance, which is known to be preferred by some designers.
- the deep reveal can be more easily fabricated into corner panels than shallow reveals. Bent or folded corner panels are the most common applications in this regard.
- Vertical joints created at the ends of horizontal panels can be treated in several ways. First, they can be filled with opened extruded gasketry, which will allow water to drain from the enclosed joint pocket to the vertical joint. Second, a solid closed-cell foam gasket can be used to keep water out of the vertical joint .
- the method of joint design as presented will allow the engagement of multiple panel thickness. For example, a thick panel can be engaged to a thin panel and vice versa. This is accomplished by having a common top edge of panel regardless of thickness. (See Figures 8- 10) .
- the inventive joint can be used in either a horizontal or vertical orientation. This will be helpful in allowing fewer changeovers .
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP99951689A EP1131509A1 (en) | 1998-11-19 | 1999-09-30 | Composite joinery |
CA002351846A CA2351846C (en) | 1998-11-19 | 1999-09-30 | Composite joinery |
MXPA01004994A MXPA01004994A (en) | 1998-11-19 | 1999-09-30 | Composite joinery. |
AU64077/99A AU6407799A (en) | 1998-11-19 | 1999-11-09 | Composite joinery |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/196,050 | 1998-11-19 | ||
US09/196,050 US6253511B1 (en) | 1998-11-19 | 1998-11-19 | Composite joinery |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2000031357A1 true WO2000031357A1 (en) | 2000-06-02 |
Family
ID=22723937
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1999/022810 WO2000031357A1 (en) | 1998-11-19 | 1999-09-30 | Composite joinery |
Country Status (6)
Country | Link |
---|---|
US (4) | US6253511B1 (en) |
EP (1) | EP1131509A1 (en) |
AU (1) | AU6407799A (en) |
CA (1) | CA2351846C (en) |
MX (1) | MXPA01004994A (en) |
WO (1) | WO2000031357A1 (en) |
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Also Published As
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US20010004816A1 (en) | 2001-06-28 |
CA2351846C (en) | 2005-04-05 |
CA2351846A1 (en) | 2000-06-02 |
AU6407799A (en) | 2000-06-13 |
US6253511B1 (en) | 2001-07-03 |
US6627128B1 (en) | 2003-09-30 |
US20010009085A1 (en) | 2001-07-26 |
EP1131509A1 (en) | 2001-09-12 |
MXPA01004994A (en) | 2006-02-22 |
US6968659B2 (en) | 2005-11-29 |
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