WALL PANEL JOINT APPARATUS AND SYSTEM USING SAME
A wall panel joint apparatus and a system using same is disclosed. The wall panel joint includes a perimeter joint body having a predetermined size and shape. The perimeter joint body floatably attaches to at least two wall panels. Embodiments include where the wall panel joint includes one, two, or more chambers in addition to the wall cavity. The system includes at least two wall panel joints that attach the wall panels to an architectural wall. At the point of intersection of the joints, the joints are mitered. The system also includes a wall attachment device and a means for attaching the joint to the wall attachment device. The system is liquid water impermeable, air permeable, and water vapor permeable system, providing a ventilated, waterproof wall panel attachment joints for use in same.
The present application is a continuation-in-part application of U.S. patent application Ser. No. 11/336,242 filed on Jan. 20, 2006 which claims the benefit of Provisional Patent Application Ser. No. 60/645,101 filed Jan. 20, 2005 and Provisional Patent Application Ser. No. 60/655,370 filed Feb. 23, 2005, which are incorporated herein by reference.
TECHNICAL FIELDThe present invention relates to wall panel joints and systems for wall panel application.
BACKGROUND INFORMATIONArchitectural panel has been in use for many years. All architectural panel systems can be classified into two major categories, namely, “face-sealed” and “vented rainscreen” systems.
Face-sealed systems include all systems with joinery that make use of sealant in the joinery whereby the system is substantially impermeable to either water or air. Achieving complete face seal is the very basis of all face seal systems. Sealant can be caulking, gasket, or another sealant of similar function. However, the lack of permeability/venting to either water vapor or air makes this system problematic.
On the contrary, vented rainscreen systems are designed to allow for permeability through the joinery, known as vents. The vents allow for breathability and rapid pressure equalization within the system cavity. However, these systems allow water to penetrate, causing water damage which is also problematic.
Unfortunately, there are deficiencies in conventional wall panel systems that lead to water damage and/or lack of venting capability. Furthermore, the systems have numerous distinct components that are required to build the conventional wall panel systems.
SUMMARYIn contrast to the above-described wall panel systems, the instant system has a symmetric panel structure with a wall panel joint having a pair of perimeter clips and at least two filler strips defining at least one chamber in addition to a wall cavity. The chamber provides for pressure equalization by increasing the air pressure within the chamber until it equals the applied wind pressure. Furthermore, the configuration of the flange portion of the outer strip flange projecting higher like the mounting flange results in blocking water. When the pressures are equal, water cannot enter the chamber. This state is attained quickly. Thus, the wall panel joints allow the wall panel system to attain optimal ventilation within the system, but prevent and minimize water entry. Furthermore, the system in addition to the pressure equalization chamber provides an internal gutter system and allows for thermal movement between adjacent wall panel units.
One embodiment is directed to a wall panel system which includes a plurality of wall panel units. Each wall panel unit has a wall panel and a plurality of perimeter clips. Each wall panel has a planar surface and a plurality of mounting flanges. The mounting flanges are generally perpendicular to the planar surface.
Each perimeter clip includes a body and a panel flange extending from the body. The panel flange is adapted to engage with one of the mounting flanges of one of the wall panels. The perimeter clips have at least a pair of strip flanges extending from the body. The strip flanges and the body define at least a pair of pockets. An attachment clip engages a pair of the perimeter clips for retaining the perimeter clips and the associated wall panel of the wall panel unit.
A pair of filler strips is associated with a pair of perimeter clips of the plurality of perimeter clips. The filler strips with the pair of perimeter clips define a wall panel joint. Each of the filler strips has a pair of receiving edges. Each of the filler strips extends between adjacent perimeter clips with a first receiving edge received in a pocket of one of the perimeter clips and the second receiving edge received in a pocket of the other perimeter clip. The pair of filler strips defines a chamber interposed between the adjacent perimeter clips and the filler strip for allowing pressure equalization while minimizing water entry into the wall cavity.
In some arrangements, the mounting flanges of each wall panel are four mounting flanges including a top horizontal mounting flange, a bottom horizontal mounting flange, and a pair of vertical mounting flanges. Each perimeter clip is identical and mountable on vertical mounting flanges and horizontal mounting flanges.
In an embodiment, each perimeter clip is identical and the adjacent pair of perimeter clips, the pair of perimeter clips, with the filler strips define the wall panel joint. The perimeter clips are positioned mirrored to each other such that the pockets align with each other.
In an embodiment, the wall panel system for securing to a wall of a building includes at least one wall securing device secured to the wall of the building. The attachment clip is carried by the at least one wall securing device wherein the wall panel units and the wall of the building define a wall cavity having a pressure equal to the outside atmosphere while not infiltrated by rain.
In an embodiment, the pair of strip flanges includes an outer strip flange, a middle strip flange, and an inner strip flange projecting from the body of the perimeter clip. The outer strip flange defines an “U” shaped outer pocket of the pockets. The middle strip flange and the inner strip flange define an “U” shaped inner pocket of the at least a pair of pockets.
In some arrangements, a middle strip flange is interposed between the outer strip flange and the inner strip flange. The inner strip flange has varying thickness including a main portion and a thinner projection portion that extends from the main portion away from the body of the perimeter clip. A protrusion of the inner strip flange projects from the body and the main portion projects away from the thinner projection portion.
In some arrangements, each perimeter clip is identical and the adjacent perimeter clips are positioned mirrored to each other such that the “U” shaped inner pockets align with each other. The pair of filler strips includes an inner filler strip that is received by and extends between the “U” shaped inner pockets of the adjacent perimeter clips. The thinner projection portion and the inner filler strip define an arm receiving space for receiving an upper arm portion of the at least one attachment clip.
In an embodiment, the attachment clip has a pair of grooves for accepting the inner strip flange of one of the perimeter clips wherein one of the perimeter clips is for holding and supporting the weight of the perimeter clip and the wall panel of the wall panel unit. The upper arm portion of the attachment clip is received in the arm receiving space interposed between the filler strip and thinner projection of the flange for limiting motion of the perimeter clip in a direction perpendicular to the planar portion of the wall panel.
In an embodiment, the adjacent mounting flanges of the adjacent wall panel and the outer filler strip define a gutter channel for channeling water.
In an embodiment, each perimeter clip is identical and mountable on vertical mounting flanges and horizontal mounting flanges of the wall panels. The adjacent pair of perimeter clips with the filler strips defining the wall panel joint, are positioned mirrored to each other such that the pockets align with each other. The outer flange has a tip flange portion that extends further towards the other wall panel of the wall panel joint than the respective mounting flange such that any water entering the outer pocket will drain over the mounting flange rather than enter the chamber.
In an embodiment, the perimeter clip has at least three strip flanges and at least three pockets defined by the at least three strip flanges and the body. There are at least three filler strips. Each of the filler strips has a pair of receiving edges. Each of the filler strips extends between adjacent perimeter clips with a first receiving edge received in a pocket of one of the perimeter clips and the second receiving edge received in a pocket of the other perimeter clip. There are at least two chambers wherein each chamber is interposed between the adjacent perimeter clips and a pair of the at least three filler strips for allowing pressure equalization while minimizing water entry.
In an arrangement, the at least one pair of strip flanges extending from the body includes an outer strip flange, a middle strip flange, and an inner strip flange. The outer strip flange defines a “U” shaped outer pocket. The middle strip flange and the inner strip flange define a “U” shaped inner pocket. The pair of filler strips includes an outer filler strip extending between the “U” shaped outer pocket of an adjacent perimeter clip and an inner filler strip extending between the “U” shaped inner pocket of the adjacent perimeter clip. The outer filler strip and the inner filler strip define a chamber interposed between the adjacent perimeter clips and the filler strip for allowing pressure equalization while minimizing water entry.
In an arrangement, the wall panel system is secured to a building having a wall structure. The plurality of wall panel units includes at least four wall panel units. Each wall panel has four mounting flanges including a top horizontal mounting flange, a bottom horizontal mounting flange, and a pair of vertical mounting flanges. Each perimeter clip is identical and mountable on vertical mounting flanges and horizontal mounting flanges. The adjacent perimeter clips are positioned mirrored to each other such that the pockets align with each other. A wall securing device is associated with a corner of each of the plurality of wall panel units and is secured to the wall structure of the building. An attachment clip is carried by each of the wall securing devices wherein the wall panel units and the wall of the building define a wall cavity having a pressure equal to the outside atmosphere while not infiltrated by rain.
In an embodiment, a wall panel joint includes a pair of perimeter clips and a pair of filler strips. Each perimeter clip includes a body, a panel flange extending from the body, and at least a pair of strip flanges. The panel flange is adapted to engage with one of the mounting flanges of one of the wall panels. The strip flanges and the body define at least a pair of pockets. Each of the filler strips has a pair of receiving edges. Each of the filler strips extends between adjacent perimeter clips with a first receiving edge received in a pocket of one of the perimeter clips and the second receiving edge received in a pocket of the other perimeter clip. The pair of filler strips defines a chamber interposed between the adjacent perimeter clips and the filler strips for allowing pressure equalization while minimizing water entry.
In one embodiment, a method of installing a wall panel system includes providing a plurality of wall panel units. Each unit has a wall panel and four perimeter clips. Each wall panel has a planar surface and four mounting flanges. The mounting flanges are generally perpendicular to the planar surface.
A plurality of wall securing devices are mounted to the wall structure of the building. The wall securing devices are positioned on the wall structure such that there is at least one wall securing device associated with each corner of each of the plurality of wall panel units. A plurality of attachment clips are mounted to the perimeter clip associated with the top horizontal mounting flange of the wall panel of at least one of the wall panel units by securing a pair of grooves on the attachment clip around an inner strip flange of the at least a pair of strip flanges of the perimeter clip. A plurality of attachment clips are mounted to the wall securing device located in proximity to where the bottom horizontal mounting flange of the wall panel of at least one of the wall panel units is to be located. The perimeter clip of the bottom horizontal mounting flange of the wall panel of at least one of the wall panel units is positioned such that the plurality of attachment clips mounted to the wall securing device have an upper arm portion located in an arm receiving space defined by the inner strip flange of the perimeter clip and a filler strip.
The plurality of attachment clips are secured to the perimeter clip associated with the top horizontal mounting flange of the wall panel of at least one of the plurality of the wall panel units to the associated plurality of wall securing devices mounted to the wall structure of the building.
A pair of filler strips is positioned with at least one of the perimeter clips of at least one of the wall panel units. The steps of mounting of a plurality of wall securing devices, mounting a plurality of attachment clips, positioning the perimeter clip and the securing the plurality of attachment clips are repeated until the wall panel system is completely secured to the building with a wall panel joint that has at least one chamber interposed between the adjacent perimeter clips and the filler strips allowing pressure equalization while minimizing water entry.
These aspects of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the appended claims and accompanying drawings.
These and other features and aspects of the present invention will be better understood by reading the following detailed description of preferred embodiments, taken together with the drawings wherein:
A wall panel system that has a symmetric panel structure with a wall panel joint having a pair of perimeter clips and at least two filler strips defining at least one chamber in addition to a wall cavity. The chamber provides for pressure equalization by increasing the air pressure within the chamber until it equals the applied wind pressure. When the pressures are equal, water cannot enter the chamber. This state is attained quickly. Furthermore, the configuration of the flange portion of the outer strip flange projecting higher like the mounting flange results in blocking water. Thus, the wall panel joints allow the wall panel system to attain optimal ventilation within the system, but prevent and minimize water entry. Furthermore, the system, in addition to the pressure equalization chamber, provides an internal gutter system and allows for thermal movement between adjacent wall panel units.
Referring to
Still referring
Still referring to
In one embodiment, the wall panels 24 are made of an aluminum composite material (ACM) that has two sheets of prefinished 0.020″ aluminum (85% recycled content) bonded to a low-density polyethylene core. The perimeter clips 26 are extruded and made of aluminum alloy such as 6061 aluminum. The filler strips 28 are made of either ACM or a contrasting material. The attachment clip 30 and the wall securing device 32 are made of aluminum alloy. It is recognized that other metals and materials can be used including zinc, copper, stainless steel, and titanium.
Referring to
In addition, the perimeter clip 26 has an outer strip flange 48. The outer strip flange 48 forms a “U” shaped outer pocket 50. The perimeter clip 26 also has a middle strip flange 52 and an inner strip flange 54. The middle strip flange 52 and the inner strip flange 54 form a “U” shaped inner pocket 56.
Still referring to
Still referring to
The wall joint 40 includes the pair of perimeter clips 26 and the filler strips 28. The perimeter clips 26, while identical, have one of the adjoining or adjacent clips 26 flipped such that the perimeter clips 26 mirror each other. The wall joint 40 is symmetrical about an axis that is perpendicular to the filler strips 28; the axis extends up and down in
Referring to
The perimeter clips 26 have the panel flange 44 for securing to the wall panel 24. The panel flange 44 forms a right angle to engage the planer portion 34 and the mounting flange 36 of the wall panel 24. The perimeter clip 26 has the outer strip flange 48 to form the “U” shaped outer pocket 50. The middle strip flange 52 and an inner strip flange 54 of the perimeter clip 26 form the “U” shaped inner pocket 56.
Still referring to
Still referring to
The upper arm portion 82 of the attachment clip 30 is received in the arm receiving space 76 defined by the thinner projection portion 74 of the inner strip flange 54 and the outer filler strip 60. The “C” channel portion 84 of the attachment clip 30 has a pair of grooves 90 that receives the protrusion 76 and the top of the thinner projection 74 of the outer strip flange 48 of the perimeter clip 26.
The flange portion 68 of the outer strip flange 48 projects higher than the mounting flange 36. Therefore, if any water works its way into the “U” shaped pocket 50, the water will drain out over the mounting flange 36 rather than enter the chamber 64.
Still referring to
The wall securing device 32 is attached to a wall structure 92 of a building 94 and secures the perimeter clip 26 to the wall structure 92 by connecting the attachment clip 30 to the wall securing device 32. Although in the exemplary embodiment, the wall securing device 32 is a subgirt, in other embodiments, any device capable of securing the wall panel joint 40 to the wall structure 92 can be used.
The perimeter clip 26 floats on the attachment clip 30 to allow for free movement in response to thermal expansion. The attachment clip 30 is made from the same material as the perimeter clip 26.
Although the terms “horizontal” and “vertical” are used herein, the terms are merely used for distinction purposes. In some embodiments, the horizontal joint can be used in both the horizontal and vertical joint in the system. Following, both vertical and horizontal joints can be attached to a wall securing device. When the horizontal joints are used as both the vertical and horizontal joints in the system, the horizontal joint is thus representative of both joints in the system.
Referring to
Referring to
As an example of installing the wall panel system 20, a plurality of 8 feet by 16 feet wall panel units 20 are mounted as the skin of a building. Each wall panel unit 20 has a wall panel 24 that is 8 feet high and 16 feet in length. The rectangular wall panel 24 has a perimeter clip 26 mounted on each edge to the mounting flange 36 as seen in
A series of wall securing devices 32 are secured to the building near ground level spaced apart based upon the structure of the building, but typically 4 to 8 feet apart. An attachment clip 30 is secured to each of the wall securing devices 32 using a fastener 88.
A series of attachment clips 30 are secured to the inner strip flange 54 at the top of the wall panel unit 22 by the “C” channel portion 84 engaging the thinner projection 74 and the protrusion 76. In one embodiment, the attachment clips 30 are attached to the perimeter clip 26 prior to the perimeter clip 26 being secured to the wall panel 24. This wall panel 24 with the four perimeter clips 26 is mitered and sealed at the job site with attachment clips 30 on one edge, the top edge. The wall panel unit 22, such as 22a in
The adjacent panels both vertically and horizontally, such as 22e and 22f in
The process is continued until the entire wall panel system 20 is built. As indicated above, the purpose of the wall panel system 20 is to allow pressure equalization between the outside environment 116 and the wall cavity 114, as best seen in
The length and width of the joints will vary depending on the architectural structure in which they are being used to hold wall panels. Thus, the joints can be any length or width desired.
Referring now to
A gap 66 is formed between the receiving edge 62 of each of the respective filler strips 58, 60 and the “U” shaped pocket 50 and 56 of the perimeter clips 26. This gap 66 is designed for ventilation and thermal movement. These gaps 66 allow for pressure equalization and permeability through impermeable material.
In practice, kinetic energy (wind) will increase the air pressure within the chamber until it equals the applied wind pressure. When the pressures are equal, water cannot enter the chamber. This state is attained quickly. Thus, the joints allow the system to attain optimal ventilation within the system, but prevent and minimize water entry. The joints shown in
Referring to
In addition, the perimeter clip 26 has the outer strip flange 48 which forms the “U” shaped outer pocket. The perimeter clip 26 also has the middle strip flange 52 and the inner strip flange 54 which forms the “U” shaped inner pocket 56.
Still referring to
Still referring to
Referring now to
The pair of adjacent perimeter clips 132 in conjunction with the inner filler strip 58 and the extreme inner filler strip 136 forms a second chamber 146.
Although embodiments showing wall panel joints having 2 and 3 filler strips 28 are shown, the invention includes wall panel joints having two or more filler strips 28 and one or more chambers. Although not shown in the exemplary embodiment, the perimeter clip body can have more than two chambers. For each filler strip added to the joint, a chamber is formed. It is recognized that the perimeter clips need to be modified to include additional pockets to retain the filler strip.
Again, the joint shown in
The joints are shaped to provide ventilation, pressure equalization chamber buffer(s), internal gutter systems, and thermal movement. The ventilation's function is to allow for permeability through impermeable cladding material. This second (and third, etc) pressure equalization chambers are designed to prevent water penetration for the extreme cases of kinetic energy due to a torrential rain storm or its equivalent. In addition, under extreme wind conditions with wider frequency range, the second, third, etc., chambers act as secondary buffers for effective pressure equalization. Weeps located at the bottom of the wall panel allow for escape from the wall cavity.
One embodiment of the single chamber system includes at least one single chamber vertical joint (shown in
The wall panels used in the art include homogenous and composite wall panels. These are not limited to any substance, whether solid or composite, and include plastic, aluminum, zinc, platinum, titanium, copper, steel, and any other metal or material that can be used to make either homogenous or composite wall paneling.
EXAMPLESReferring again to
Air infiltration, water penetration, and structural performance tests of the system installed in a laboratory test chamber were performed. Wall Assembly A was tested on Apr. 8, 2005; Wall Assembly B was tested for water penetration in accordance with ASTM: E 331 on Apr. 22, 2005, and for water penetration in accordance with ASTM: E 331 but modified to monitor air flow as openings were cut in the back-up wall on May 6 and Jun. 7, 2005. The following comments describe the test procedures and results for each wall assembly.
DESCRIPTIONS OF WALL ASSEMBLIESWALL ASSEMBLY A—APR. 8, 2005: water penetration air infiltration and structural tests were performed on Wall Assembly A.
TEST SPECIMEN—DESCRIPTION
The following wall assembly was mounted in a laboratory test chamber:
Dimension of Wall: 10 feet high by 10 feet wide
Framing: 2″×6″ steel stud and stud track, 14-gauge
Sheathing: ⅝″ thick Dens-Glass
Air Barrier Membrane: Carlisle CCW-705 sheet membrane waterproofing system was installed over the Dens-Glass sheathing. An 18-gauge galvanized steel X deep hat bar was installed over the insulation. Lymo aluminum composite panels were attached to the hat bar with a continuous piece of extruded aluminum. Each panel contained two weep holes. Horizontal flashing was installed over the top of the system.
WALL ASSEMBLY B—APR. 22, MAY 6, AND JUN. 7, 2005: water penetration and air infiltration tests were performed on Wall Assembly B.
TEST SPECIMEN—DESCRIPTION
The following wall assembly was mounted in a laboratory test chamber:
Dimension of Wall: 10 feet high by 10 feet wide
Framing: 2″×6″ steel stud and stud track, 14-gauge
Sheathing: ⅜″ thick plexiglass
The joints between abutting sheets of plexiglass were back-sealed against the steel stud framing with Dow silicone sealant. At perimeter joints, three to four inch wide strips of Carlisle CCW-705 sheet waterproofing membrane were installed.
Over all perimeter joints between the perimeter of the plexiglass and the chamber walls, at vertical joints between the plexiglass sheets, and horizontally over the surface of the plexiglass where fasteners from the plexiglass to the studs were placed and where the 18-gauge galvanized steel ½″ deep bars were installed.
Panel System: Two metal panel systems were installed. The directions of “right” and “left” are from the interior view:
System 1 (Right Side): Standard dry seam metal panel system (prior art).
System 2 (Left Side): Lymo Dry Seam 3000 panel system with double-spline system (double compartment or chamber system embodiment of present invention)
TEST PROCEDURES
A. Air infiltration testing was conducted in accordance with applicable provisions of ASTM Designation: E 283, “Standard Test Method for Measurement of Air Leakage Through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure Differences Across the Specimen.”
B. Water penetration testing was conducted in accordance with applicable provisions of ASTM Designation: E 331, “Standard Test Method for Determination of Water Penetration of Exterior Windows, Curtain Walls, and Doors by Uniform Static Air Pressure Difference.” This test method was modified by making openings in the back-up wall and recording the pressure change and air flow from the chamber while the volume of air being removed from the chamber was maintained at a constant rate. The modifications were used during water testing of Wall Assembly B.
TEST RESULTS
WALL ASSEMBLY A—APR. 8, 2005
1. AIR INFILTRATION@1.57 PSF
Measured Air Leakage: 0.4 cfm
Calculated Air Infiltration: 0.004 cfm per square foot
The allowable increase is 0.004 cubic feet per square foot. The assembly met the requirement for air infiltration of an air barrier in the Massachusetts Energy Code.
2. WATER PENETRATION
Water was applied to the ‘exterior’ of the panel system at the standard rate of 5.0 gallons per hour per square foot while a negative chamber pressure of 6.24 psf was maintained on the interior of the wall assembly.
Test 1 @6.24 psf: No leakage was observed on the ‘interior’ of the chamber or on the surrounding construction during or following the 15-minute test period.
Test 2 @15 psf: No leakage was observed on the ‘interior’ of the chamber or on the surrounding construction during or following the 15-minute test period.
WALL ASSEMBLY B—APR. 22, MAY 6, AND JUN. 7, 2005
Water was applied to the exterior of the panel system at the standard rate of 5.0 gallons per hour. The following observations were made during the tests both before and after holes were made in the sheathing of the back-up wall, with air flow and pressure readings taken as part of the observations. The directions of “right” and “left” are from the interior view.
Test 1 A 0 psf differential pressure was applied to the test chamber. Water was observed running down in the wall cavity behind the standard dry seam metal panel system (right side). No water was observed in the wall cavity behind the Lymo Dry Seam 3000 Panel System (left side).
Test 2 A 15 psf differential pressure was applied to the test chamber behind the wall system. Water was observed running down in the wall cavity behind the standard dry seam metal panel system (right side). No water was observed in the wall cavity behind the Lymo Dry Seam 3000 Panel System (left side). The air flow from the test chamber recorded during this test was 97 cfm.
Test 3 A ¼″ diameter hole was drilled through the sheathing on the back-up wall as the vacuum motor and valve controlling the rate of air extraction from the test chamber were not changed from the settings for the test chamber differential pressure of 15 psf. The pressure reading was 14.35 psf. The air flow reading was 86 cfm.
Water was observed running down in the wall cavity behind the standard dry seam metal panel system (right side). No water was observed in the wall cavity behind the Lymo Dry Seam 3000 Panel System (left side).
Test 4 A second ¼″ diameter hole was drilled through the sheathing on the back-up wall as the vacuum motor and valve controlling the rate of air extraction from the test chamber were not changed from the settings for the test chamber differential pressure of 15 psf. The pressure reading was 13.31 psf. The air flow reading was 91 cfm.
Water was observed running down in the wall cavity behind the standard dry seam metal panel system (right side). No water was observed in the wall cavity behind the Lymo Dry Seam 3000 Panel System (left side).
Test 5 A third ¼″ diameter hole was drilled through the sheathing on the back-up wall as the vacuum motor and valve controlling the rate of air extraction from the test chamber were not changed from the settings for the test chamber differential pressure of 15 psf. The pressure reading was 12.79 psf. The air flow reading was 90.6 cfm.
Water was observed running down in the wall cavity behind the standard dry seam metal panel system (right side). No water was observed in the wall cavity behind the Lymo Dry Seam 3000 Panel System (left side).
Test 6 A 12″×12″ hole was cut through the sheathing on the back-up wall as the vacuum motor and valve controlling the rate of air extraction from the test chamber were not changed from the settings for the test chamber differential pressure of 15 psf. The pressure reading was 0.16 psf. The air flow reading was 81.3 cfm.
Water was observed running down in the wall cavity behind the standard dry seam metal panel system (right side). No water was observed in the wall cavity behind the Lymo Dry Seam 3000 Panel System (left side).
COMMENTS AND CONCLUSIONWater was observed in the wall cavity behind a standard dry seam metal wall panel system prior to allowing the pressure drop to occur in the wall cavity. The Lymo 3000 double dry seam panel system was not observed to leak into the wall cavity prior to allowing the pressure drop to occur in the wall cavity.
ADDITIONAL TESTINGAdditional testing was preformed on Feb. 27 and 28, 2007. The testing was performed in accordance with AAMA 508-05, Voluntary Test Method and Specification for Pressure Equalized Rain Screen Wall Cladding Systems. The testing included air infiltration; cyclic static air pressure differential; static pressure water resistance; and dynamic pressure water resistance.
The wall utilized 0.160″ thick aluminum composite cladding panels on the exterior. A 6¼″ by 6¼″ aluminum flashing was installed over the 2×12 at the sill of the mock-up. An aluminum Z-channel was installed over the flashing and the top edge, and was sealed with Carlisle EZ Flash. The base of the flashing and Z-channel were secured to the 2×12 with a continuous aluminum angle, secured with 1×1″ screws spaced 12″ on center. Panels were attached to the test wall and the sill with a continuous extruded aluminum channel clip which was fastened to the aluminum angle with #12×1″ screws spaced 16″ on center. The head of the system utilized a continuous 1⅝″ by 3″ aluminum angle secured to the 2×12 with #12×1″ screws spaced 12″ on center. The panel was secured at the head with 3¼″ long aluminum clips spaced 16″ on center which were fastened to the aluminum angle sealed with butyl. The horizontal joint was comprised of a 3″ wide continuous extruded aluminum clip secured to the panels by a subgirt and a #12×1″ screw. An aluminum composite material (ACM) filler strip 28 was installed inside the aluminum perimeter clip 26. The subgirt was fastened to the steel studs with #14×3½″ screws. The vertical joint was comprised of a 3″ wide continuous extruded aluminum clip which was secured to the panels with pop rivets. An ACM filler strip 28 was installed inside the aluminum perimeter clip.
Test Set-up:
An 8′0″ wide by 8′0″ high standard wall was constructed with 14 gauge steel studs 16″ on center inside a 2×12 wood buck. The stud wall was covered by a ¼″ thick sheet of clear acrylic sealed and fastened to the exterior of the wall to simulate an air/water barrier. The Pressure Equalized Rain Screen Wall Cladding (PRWC) system was then installed onto the acrylic in a manner consistent with normal construction procedures for the system. The acrylic was calibrated to a pre-determined air leakage rate by drilling ⅛″ diameter holes in the backside of the acrylic, in a uniform pattern, making sure to create an even pressure drop and leakage rate across the wall and in each quadrant.
The Air Infiltration test was pursuant to ASTM E 283-04, Standard Test Method for Determining the Rate of Air Leakage Through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure Differences Across the Specimen. Testing was conducted at 1.57 psf positive static air pressure difference.
The standard requires infiltration of between 0.418 cfm/ft2 and 0.511 cfm/ft2 for 1.57 psf (25 mph). The result of the testing was 0.464 cfm/ft2.
The Cyclic Static Air Pressure Differential test was pursuant to ASTM E 1233-00, Standard Test Method for Structural Performance of Exterior Windows, Curtain Walls, and Doors by Cyclic Static Air Pressure Differential. Testing was conducted at 25 psf in 100 three-second cycles. The standard allows 0.08 seconds. The results were less than 0.08 seconds so the test was passed.
The Static Pressure Water Resistance test was pursuant to ASTM E 331-00, Standard Test Method for Water Penetration of Exterior Windows, Curtain Walls, and Doors by Uniform Static Air Pressure Difference. Testing was conducted at 15.0 psf positive static air pressure difference for a 15 minute duration. Water was applied to the mock-up at a minimum rate of 5 gal/ft2/hr. The standard allows up to 0.64 ounces of water. Zero ounces penetrated so the test was passed. Cavity pressure readings were taken in the top left and bottom right (interior view) quadrants.
The standard, like the static standard, allows up to 0.64 ounces of water to penetrate. Zero ounces penetrated so the test was passed. In the tests, water entered through the weeps and filled the gutters but did not overflow. Water came down the second right most vertical member at bottom. Furthermore, the test was conducted at a higher water penetration pressure than required.
While the principles of the invention have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the invention. Other embodiments are contemplated within the scope of the present invention in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the following claims.
Claims
1. A wall panel system comprising:
- a plurality of wall panel units, each unit having a wall panel and a plurality of perimeter clips; each wall panel having a planar surface and a plurality of mounting flanges, the mounting flanges generally perpendicular to the planar surface; each perimeter clip including: a body; a panel flange extending from the body, the panel flange adapted to engage with one of the mounting flanges of one of the wall panels; and at least a pair of strip flanges extending from the body, the at least a pair of strip flanges and the body defining at least a pair of pockets;
- a pair of filler strips associated with a pair of perimeter clips of the plurality of perimeter clips, the filler strips with the pair of perimeter clips defining a wall panel joint, each of the filler strips having a pair of receiving edges, each of the filler strips extending between adjacent perimeter clips with a first receiving edge received in a pocket of one of the perimeter clips and the second receiving edge received in a pocket of the other perimeter clip, the pair of filler strips defining a chamber interposed between the adjacent perimeter clips and the filler strip for allowing pressure equalization while minimizing water entry; and
- at least one attachment clip, the attachment clip engaging a pair of the perimeter clips for retaining the perimeter clips and the associated wall panel of the wall panel unit.
2. A wall panel system of claim 1 wherein
- the plurality of mounting flanges of each wall panel are four mounting flanges including a top horizontal mounting flange, a bottom horizontal mounting flange, and a pair of vertical mounting flanges; and
- each perimeter clip is identical and mountable on vertical mounting flanges and horizontal mounting flanges.
3. A wall panel system of claim 1 wherein each perimeter clip is identical and the adjacent pair of perimeter clips with the filler strips defining the wall panel joint, are positioned mirrored to each other such that the pockets align with each other.
4. A wall panel system of claim 1 for securing to a wall of a building further comprising at least one wall securing device secured to the wall of the building, the at least one attachment clip carried by the at least one wall securing device wherein the wall panel units and the wall of the building define a wall cavity having a pressure equal to the outside atmosphere while not infiltrated by rain.
5. A wall panel system of claim 1 wherein the at least a pair of strip flanges includes an outer strip flange projecting from the body of the perimeter clip, the outer strip flange defines an “U” shaped outer pocket of the at least a pair of pockets and the at least a pair of strip flanges includes a middle strip flange and an inner strip flange that project from the body of the perimeter clip, the middle strip flange and the inner strip flange define an “U” shaped inner pocket of the at least a pair of pockets.
6. A wall panel system of claim 5 wherein the middle strip flange is interposed between the outer strip flange and the inner strip flange, the inner strip flange having a varying thickness including a main portion and a thinner projection portion that extends from the main portion away from the body of the perimeter clip and a protrusion that projects from the body and the main portion away from the thinner projection portion.
7. A wall panel system of claim 6 wherein
- each perimeter clip is identical and the adjacent perimeter clips are positioned mirrored to each other such that the “U” shaped inner pockets align with each other;
- the pair of filler strips including an inner filler strip that is received by and extends between the “U” shaped inner pockets of the adjacent perimeter clips;
- the thinner projection portion and the inner filler strip define an arm receiving space for receiving a portion of the at least one attachment clip.
8. A wall panel system of claim 7 wherein the attachment clip has a pair of grooves for accepting the inner strip flange of one of the perimeter clips wherein one of the perimeter clips is for holding and supporting the weight of the perimeter clip and the wall panel of the wall panel unit and the upper arm portion of the attachment clip is received in the arm receiving space interposed for limiting motion of the perimeter clip in a direction perpendicular to the planar portion of the wall panel.
9. A wall panel system of claim 1 for securing to a wall of a building further comprising:
- at least one wall securing device secured to the wall of the building, the at least one attachment clip carried by the at least one wall securing device wherein the wall panel units and the wall of the building define a wall cavity;
- the plurality of mounting flanges of each wall panel are four mounting flanges including a top horizontal mounting flange, a bottom horizontal mounting flange, and a pair of vertical mounting flanges;
- the at least a pair of strip flanges of the perimeter clip includes an outer strip flange, a middle strip flange, and an inner strip flange, each flange projecting from the body of the perimeter clip, the outer strip flange defines an “U” shaped outer pocket of the at least a pair of pockets, the middle strip flange and the inner strip flange define an “U” shaped inner pocket of the at least a pair of pockets, the middle strip flange is interposed between the outer strip flange and the inner strip flange, the inner strip flange having a varying thickness including a main portion and a thinner projection portion that extends from the main portion away from the body of the perimeter clip and a protrusion that projects from the body and the main portion away from the thinner projection portion; and
- each perimeter clip is identical and mountable on vertical mounting flanges and horizontal mounting flanges of the wall panels, the adjacent pair of perimeter clips with the filler strips defining the wall panel joint, are positioned mirrored to each other such that the pockets align with each other, wherein the outer flange has a tip flange portion that extends further towards the other wall panel of the wall panel joint than the respective mounting flange such that any water entering the outer pocket will drain over the mounting flange rather than enter the chamber.
10. A wall panel system of claim 1 wherein
- each of the perimeter clips wherein the at least a pair of strip flanges includes at least three strip flanges, wherein the at least a pair of pockets being at least three pockets defined by the at least three strip flanges and the body;
- the pair of filler strips includes at least three filler strips, each of the filler strips having a pair of receiving edges, each of the filler strips extending between adjacent perimeter clips with a first receiving edge received in a pocket of one of the perimeter clips and the second receiving edge received in a pocket of the other perimeter clip; and
- the chamber being at least two chambers wherein each chamber is interposed between the adjacent perimeter clips and a pair of the at least three filler strips for allowing pressure equalization while minimizing water entry.
11. A wall panel system of claim 1 wherein:
- the at least a pair of strip flanges extending from the body includes an outer strip flange, a middle strip flange, and an inner strip flange, the outer strip flange defining a “U” shaped outer pocket of the at least a pair of pockets and the middle strip flange and the inner strip flange defining a “U” shaped inner pocket of the at least a pair of pockets; and
- the pair of filler strips includes an outer filler strip extending between the “U” shaped outer pocket of an adjacent perimeter clip and an inner filler strip extending between the “U” shaped inner pocket of an adjacent perimeter clip, the outer filler strip and the inner filler strip defining a chamber interposed between the adjacent perimeter clips and the filler strip for allowing pressure equalization while minimizing water entry.
12. A wall panel system of claim 1 wherein the wall panel system is secured to a building having a wall structure, the wall panel system wherein:
- the plurality of wall panel units includes at least four wall panel units;
- the plurality of mounting flanges of each wall panel is four mounting flanges including a top horizontal mounting flange, a bottom horizontal mounting flange, and a pair of vertical mounting flanges;
- each perimeter clip is identical and mountable on vertical mounting flanges and horizontal mounting flanges and the adjacent perimeter clips are positioned mirrored to each other such that the pockets align with each other;
- at least one wall securing device associated with a corner of the plurality of wall panel units and secured to the wall structure of the building, the at least one attachment clip carried by the at least one wall securing device wherein the wall panel units and the wall of the building define a wall cavity having a pressure equal to the outside atmosphere while not infiltrated by rain.
13. A wall panel system of claim 12 wherein
- the at least a pair of strip flanges of each of the perimeter clips includes at least three strip flanges, wherein the at least a pair of pockets being at least three pockets defined by the at least three strip flanges and the body;
- the pair of filler strips includes at least three filler strips, each of the filler strips having a pair of receiving edges, each of the filler strips extending between adjacent perimeter clips with a first receiving edge received in a pocket of one of the perimeter clips and the second receiving edge received in a pocket of the other perimeter clip; and
- the chamber being at least two chambers wherein each chamber is interposed between the adjacent perimeter clips and a pair of the at least three filler strips for allowing pressure equalization while minimizing water entry.
14. A wall panel joint comprising:
- a pair of perimeter clips, each perimeter clip including: a body; a panel flange extending from the body, the panel flange adapted to engage with one of the mounting flanges of one of the wall panels; and at least a pair of strip flanges extending from the body, the at least a pair of strip flanges and the body defining at least a pair of pockets;
- a pair of filler strips, each of the filler strips having a pair of receiving edges, each of the filler strips extending between adjacent perimeter clips with a first receiving edge received in a pocket of one of the perimeter clips and the second receiving edge received in a pocket of the other perimeter clip, the pair of filler strips defining a chamber interposed between the adjacent perimeter clips and the filler strips for allowing pressure equalization while minimizing water entry.
15. A wall panel joint of claim 14 wherein each perimeter clip is identical and the adjacent perimeter clips are positioned mirrored to each other such that the pockets align with each other.
16. A wall panel joint of claim 15 further comprising at least one attachment clip, the attachment clip engaging a pair of the perimeter clips for retaining the perimeter clips.
17. A wall panel joint of claim 16 further comprising a plurality of wall panels units, each unit having a wall panel and a plurality of the perimeter clips, each wall panel having a planar surface and a plurality of mounting flanges, the mounting flanges generally perpendicular to the planar surface.
18. A wall panel joint of claim 17 wherein the wall panel system is secured to a building having a wall structure, the wall panel system wherein:
- the plurality of wall panel units includes at least four wall panel units;
- the plurality of mounting flanges of each wall panel is four mounting flanges including a top horizontal mounting flange, a bottom horizontal mounting flange, and a pair of vertical mounting flanges;
- each perimeter clip is identical and mountable on vertical mounting flanges and horizontal mounting flanges and the adjacent perimeter clips are positioned mirrored to each other such that the pockets align with each other; and
- at least one wall securing device is associated with a corner of the plurality of wall panel units and secured to the wall structure of the building, the at least one attachment clip carried by the at least one wall securing device wherein the wall panel units and the wall of the building define a wall cavity having a pressure equal to the outside atmosphere while not infiltrated by rain.
19. A method of installing a wall panel system comprising:
- providing a building having a wall structure;
- providing a plurality of wall panel units, each unit having a wall panel and four perimeter clips; each wall panel having a planar surface and four mounting flanges, the mounting flanges generally perpendicular to the planar surface; and each perimeter clip including: a body; a panel flange extending from the body, the panel flange adapted to engage with one of the mounting flanges of one of the wall panels; and at least a pair of strip flanges extending from the body, the at least a pair of strip flanges and the body defining at least a pair of pockets;
- mounting a plurality of wall securing devices to the wall structure of the building, the wall securing devices positioned on the wall structure such that there is at least one wall securing device associated with each corner of each of the plurality of wall panel units:
- mounting a plurality of attachment clips to the perimeter clip associated with the top horizontal mounting flange of the wall panel of at least one of the plurality of the wall panel units by securing a pair of grooves on the attachment clip around an inner strip flange of the at least a pair of strip flanges of the perimeter clip;
- mounting a plurality of attachment clips to the wall securing device located in proximity to where the bottom horizontal mounting flange of the wall panel of at least one of the plurality of the wall panel units is to be located;
- positioning the perimeter clip of the bottom horizontal mounting flange of the wall panel of at least one of the plurality of the wall panel units such that the plurality of attachment clips mounted to the wall securing device have an upper arm portion located in an arm receiving space defined by the inner strip flange of the perimeter clip and a filler strip;
- securing the plurality of attachment clips to the perimeter clip associated with the top horizontal mounting flange of the wall panel of at least one of the plurality of the wall panel units to the associated plurality of wall securing devices mounted to the wall structure of the building;
- positioning a pair of filler strips with at least one of the perimeter clips of at least one of the plurality of the wall panel units;
- repeating the mounting of a plurality of wall securing devices, mounting a plurality of attachment clips, positioning the perimeter clip, and securing the plurality of attachment clips until the wall panel system is completely secured to the building with defining a wall panel joint that has at least one chamber interposed between the adjacent perimeter clips and the filler strips for allowing pressure equalization while minimizing water entry.
20. A method of installing a wall panel system of claim 19 wherein
- each of the perimeter clips wherein the at least a pair of strip flanges includes at least three strip flanges, wherein the at least a pair of pockets being at least three pockets defined by the at least three strip flanges and the body;
- the pair of filler strips includes at least three filler strips, each of the filler strips having a pair of receiving edges, each of the filler strips extending between adjacent perimeter clips with a first receiving edge received in a pocket of one of the perimeter clips and the second receiving edge received in a pocket of the other perimeter clip; and
- the chamber being at least two chambers wherein each chamber is interposed between the adjacent perimeter clips and a pair of the at least three filler strips for allowing pressure equalization while minimizing water entry.
Type: Application
Filed: Apr 6, 2009
Publication Date: Feb 18, 2010
Applicant: Lymo Construction Co., Inc. (Merrimack, NH)
Inventors: Dan Lynch (Bedford, NH), Kong K. Taing (Allston, MA)
Application Number: 12/419,034
International Classification: E04B 2/00 (20060101); E04B 1/00 (20060101);