Wall Panel Systems for Rigid Wall Panels

Abstract

Wall panel systems are provided. The systems use interlocking components to attach photovoltaic (PV), ceramic, or other rigid wall panels to an exterior wall of a building.

Description

STATEMENT OF RELATED APPLICATIONS

This application is filed as a continuation-in-part patent application, and claims the benefit of U.S. patent application Ser. No. 12/829,503, which was filed on 2 Jul. 2010. That application is entitled “Dry Joint Wall Panel Attachment System,” and published as U.S. Patent Publ. No. 2010/0263314.

This parent application was a continuation-in-part of U.S. patent application Ser. No. 11/273,303 which was filed on 14 Nov. 2005 (now abandoned). That application was entitled “Dry Joint Aluminum Wall Panel Attachment System,” and published as U.S. Patent Publ. No. 2007/0119105.

These prior applications are incorporated herein in their entirety by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

BACKGROUND OF THE INVENTION

This section is intended to introduce various aspects of the art, which may be associated with exemplary embodiments of the present disclosure. This discussion is believed to assist in providing a framework to facilitate a better understanding of particular aspects of the present disclosure. The Background section should be read in this light, and not necessarily as admissions of prior art.

FIELD OF THE INVENTION

The present disclosure relates to wall panel attachment systems which include photovoltaic (PV, or solar) panels and porcelain ceramic tile (PCT) panels. The present disclosure also pertains to methods of attaching rigid wall panels to exterior wall surfaces.

DISCUSSION OF TECHNOLOGY

Attachment systems for exterior walls of buildings are known. These attachment systems are used for attaching aluminum wall panels along an exterior surface.

The known aluminum wall panel attachment systems have obstacles. Conventionally, these systems rely upon adhesive or caulk to “seal” the aluminum panel from the elements. However, under exposure to heat and cold and moisture, the adhesive or caulk breaks down. This, in turn, compromises the stability of the system and creates an undesirable appearance.

Even when such a seal is functional, there may be undesirable effects on the aluminum panels. In this respect, the interior environment can trap heat which affects the individual panels, creating “oil-canning” or popping in response to the pressure differential. In spite of such seals, such systems can also trap moisture in the wall cavity. This, in turn, results in oxidation of parts and staining or deterioration of exterior wall surfaces.

More recently, systems have been developed according to the “rainscreen principle.” This means that the wall cavity is vented, resulting in a temperature and pressure equalized system with moisture drainage. However, such systems can be difficult to install, relying on many components to be milled or adapted on-site, and requiring excessive labour costs and specialty materials. Therefore, a need exists for an improved wall panel attachment system which permits the ingress and egress of moisture behind the panels. Further, a need exists for an attachment system in which the wall panels can be attached to a wall in any sequence.

It is also desirable to modify an aluminum wall panel attachment system for use with other types of panels. For example, it is desirable for such attachment systems to accommodate photovoltaic (PV, or solar) panels. Given the increasing prevalence of solar energy use in commercial buildings, the vertical wall surfaces present a logical location for the placement of such panels. While solar panels are manufactured in a wide range of sizes and shapes, a need exists to incorporate solar panels into an innovative panel attachment system that permits flush assembly with non-solar panels and reliable operation of the solar energy collection system.

It is further desirable to modify an aluminum wall panel attachment system to accommodate the use of stiff or non-bendable panels, such as porcelain or other ceramic panels.

SUMMARY OF THE INVENTION

Wall panel systems for attaching wall panels to an exterior building wall are provided herein. In one aspect, the wall panel system provides a plurality of solar (or PV) panels that are attached to the building wall side-by-side. In another aspect, the wall panel system provides solar panels placed adjacent to aluminum (or other non-solar) wall panels. In yet another aspect, the wall panel system provides a plurality of ceramic panels that are attached to the building wall side-by-side.

First, a wall panel system is provided. The system allows for the attachment of two or more adjacent rigid wall panels to an exterior building wall. The rigid wall panels are either PV wall panels or ceramic wall panels. In one embodiment, the system includes a plurality of rigid wall panels, a plurality of bracket assemblies configured to be fastened to the exterior building wall; and a plurality of attachment clips configured to be fastened to respective bracket assemblies by a fastener and to carry the dead loads of the respective rigid wall panels. Preferably, the bracket assemblies are fabricated from steel for strength.

Each attachment clip has a central fastening surface fastened to the bracket assembly. Further, each attachment clip has a pair of integrally formed wing members. The wing members extend from a central fastening surface, preferably in a substantially symmetrical manner.

The rigid wall panel system also includes a plurality of tile perimeter strips. Each tile perimeter strip comprises a generally C-shaped member having a planar surface configured to extend along a rear surface of a respective wall panel. Each tile perimeter strip further comprises a receiving member integrally attached to the C-shaped member and having a slot adapted to engage and interlock one of the wing members of the attachment clip.

The rigid wall panels are adhesively connected to respective planar surfaces of the tile perimeter strips. The adhesive connection may be through a high-strength bonding tape, a structural silicone adhesive and sealant, or a combination of both. It is noted that while the adhesive connection may provide a substantially water-proof seal along a perimeter of the panel, the C-shaped member may have a through-opening to permit the ingress of air behind the rigid wall panels.

In a preferred embodiment using PV wall panels, the system further includes one or more cable guides. The cable guides may be attached to respective bracket assemblies. Each of the cable guides is configured to receive an electrical cable extending from the rear surface of the respective PV wall panels.

In an alternate embodiment, and as noted above, a PV wall panel may be placed on an exterior building wall adjacent to a non-PV wall panel, such as an aluminum composite panel. For this arrangement, an alternate wall panel system is provided that is a hybrid wall panel system.

The hybrid wall panel system first includes a plurality of PV (or other rigid) wall panels. In the case of solar wall panels, each PV wall panel defines a plurality of photovoltaic cells configured to convert solar energy into electrical energy. Further, each PV wall panel comprises an exterior flat surface as noted above.

In addition, the hybrid wall panel system includes a non-PV wall panel. The non-PV wall panel has an exterior flat surface and at least two side surfaces bent generally perpendicularly to the exterior flat surface. In this way, a hollow interior portion is defined inside each non-PV wall panel. Preferably, each non-PV wall panel comprises an aluminum composite material.

The hybrid wall panel system may also include a plurality of bracket assemblies. Each bracket assembly is configured to be fastened to the exterior wall. In one aspect, each bracket assembly comprises two back-to-back L-angle brackets fastened to each other to form a generally Z-shaped assembly. A first end is for attachment to the wall, and a second end is for fastening to an attachment clip.

The wall panel system also has a plurality of attachment clips. Each clip is preferably fabricated from aluminum, and is configured to be fastened to a respective bracket assembly by a fastener. Preferably, each fastener comprises a threaded fastener. The attachment clips carry the dead loads of the various wall panels.

Each attachment clip has a central fastening surface configured to be fastened to the bracket assembly. Each attachment clip further has a pair of integrally formed wing members. Each wing member extends outwardly from the central fastening surface, preferably in a substantially symmetrical manner. Preferably, isolation tape is applied between the attachment clips and the respective bracket assemblies.

The hybrid wall panel system also includes a plurality of perimeter strips. Preferably, each perimeter strip is fabricated from aluminum. Perimeter strips that support the solar or PV wall panels are referred to as tile perimeter strips; perimeter strips that support the non-PV wall panels are referred to as panel perimeter strips.

Each tile perimeter strip is configured as the tile perimeter strips described above. In this respect, each tile perimeter strip is configured to adhesively connect to a rear surface of a respective PV panel. At the same time, each panel perimeter strip is configured to be fastened to one side surface of a respective wall panel.

Each tile perimeter strip comprises a generally C-shaped member having a planar surface configured to extend along a rear surface of a respective PV wall panel. Each tile perimeter strip further comprises a receiving member integrally attached to the C-shaped member and having a slot adapted to engage and interlock one of the wing members of the attachment clip. At the same time, each panel perimeter strip comprises a generally C-shaped member configured to reside inside of and extend along an inside portion of a side surface of a respective wall panel. Further, each panel perimeter strip has a slot integrally attached to the C-shaped member adapted to engage and interlock one of the wing members of the attachment clip, thus connecting a respective non-PV wall panel to the attachment clip and, thereby, to the wall.

The hybrid wall panel system also includes one or more rivets. The rivets are placed along the side surface of the non-PV wall panels to connect the side surface of a respective wall panel to a receiving member of a panel perimeter strip.

The wall panel system may optionally include panel stiffeners. The panel stiffeners are positioned behind or on the rear surface of the PV wall panels. Panel stiffeners may also be placed behind or inside the hollow interior portion of the respective aluminum wall panels. The panel stiffeners reinforce the aluminum wall panels and prevent deforming or popping of the aluminum wall panels.

The wall panel system may further include a plurality of infill strips. Each infill strip is preferably fabricated from a substantially rigid material comprising aluminum, or a combination of aluminum and polyethylene, or of fire-retardant polyvinyl. Each of the infill strips is non-sealingly disposed within respective slots of adjoining panel perimeter strips.

With the exception of the adhesive connection of the rigid panels to the tile perimeter strips, the hybrid wall panel system is held together non-adhesively. Further, the system is ventilated at least partially through the one or more rivets to permit ingress and egress of air and moisture to provide a pressure-balanced and moisture-drained interior environment.

The above-described systems are configured to allow panels to be secured to respective bracket assemblies along the wall in any sequence. Additional wall panels may be attached to the exterior wall using additional bracket assemblies, attachment clips and panel perimeter strips.

BRIEF DESCRIPTION OF THE FIGURES

So that the manner in which the above recited features of the present invention can be better understood, certain drawings are appended hereto. It is to be noted, however, that the appended drawings illustrate only selected embodiments of the inventions and are therefore not to be considered limiting of scope, for the inventions may admit to other equally effective embodiments and applications.

FIG. 1 shows a cross-sectional view of a wall panel attachment system, in one embodiment. Here, the wall panels are aluminum panels having edges that are bent inward for connection to panel perimeter strips.

FIG. 2 is a cross-sectional view of a panel perimeter strip used in the attachment system, in one embodiment.

FIG. 3 is a cross-sectional view of an attachment clip used in the attachment system, in one embodiment.

FIG. 4 is a cross-sectional view of a panel stiffener optionally used in the attachment system, in one embodiment.

FIG. 5 shows a cross-sectional view of aluminum composite material (ACM) as may be used in the wall panels.

FIGS. 6, 7, and 8 show progressive steps in the formation of an ACM panel for use in the present system, in one embodiment. In FIG. 8, it can be seen that the opposing edges of the aluminum wall panel have been bent and then secured to respective panel perimeter strips using rivets.

FIG. 9 shows a cross-sectional view of an infill strip as may be used in the attachment system of FIG. 1.

FIG. 10 shows an enlarged cross-sectional view of an infill strip having been received within adjacent panel perimeter strips. The infill strip covers the attachment clip and fastener.

FIG. 11 is an elevational view of sub-framing or bracket assemblies used for mounting a plurality of ACM panels in the present system, in one arrangement.

FIG. 12 is a cross-sectional view of a wall panel attachment system with bracket assemblies, in one embodiment.

FIGS. 13, 14 and 15 show progressive steps in the installation of an infill strip in a wall panel attachment system, according to a first method.

FIG. 16 shows a view of the installation of lengths of infill strip in a wall panel attachment system, according to a second method.

FIG. 17 shows a view of a finished wall paneled exterior, in one embodiment. A plurality of wall panels is shown.

FIG. 18 shows a cross-sectional view of a panel perimeter strip, in an alternate arrangement.

FIGS. 19 and 20 show cross-sectional views of two versions of an alternative panel stiffener.

FIG. 21 is a cross-sectional view of a photovoltaic (PV) wall panel attachment system adjacent a non-PV wall panel attachment system, wherein the exterior surfaces remain flush with one another.

FIGS. 22 and 23 provide enlarged views of upper and lower portions of wall panel attachment systems for supporting a PV panel. Separate tile perimeter strips are shown.

FIG. 24 is a plan view of a panel placed on panel perimeter strips.

FIG. 25 is a top (or, optionally, side) view of another photovoltaic (PV) wall panel attachment system. Here, two solar wall panels are placed on an exterior wall adjacent to one another. The two solar wall panels are flush.

FIG. 26 shows cross-sectional views of a plurality of alternative attachment clips that may be used in the attachment systems herein, depending on location of the panel to be installed.

FIG. 27 shows cross-sectional views of a plurality of alternative panel perimeter strips that may be used with the attachment systems herein, depending on location of the panel to be installed.

FIG. 28 provides cross-sectional views of alternative infill strips as may be used in the attachment systems herein.

FIG. 29 is a perspective view of a rigid panel that may be adhered to an alternative tile perimeter strip. The rigid panel may be a porcelain ceramic tile (PCT) wall panel.

FIG. 30 is a top (or, optionally, a side) view of a porcelain ceramic tile (PCT) wall panel attachment system, in one embodiment. Here, two porcelain ceramic wall panels are placed on an exterior wall adjacent to one another.

FIG. 31 is a cross-sectional view of a wall panel assembly, wherein the assembly utilizes a porcelain ceramic tile (PCT) wall panel attached to panel perimeter strips. The assembly is ready for hanging.

FIG. 32 is a cross-sectional view of a PCT wall panel attachment system at an end of a wall. A porcelain ceramic tile is shown placed along the exterior of the wall. The attachment system in this view is ideally suited for use with a curtain wall sill.

FIG. 33 is a cross-sectional view of a PCT wall panel attachment system at an end of a wall, in an alternate embodiment. A porcelain ceramic tile is again shown placed along the exterior of the wall. The attachment system in this view is ideally suited for use with a curtain wall head.

FIG. 34 is still another cross-sectional view of a PCT wall panel attachment system at an end of a wall, in an alternate embodiment. A porcelain ceramic tile is again shown placed along the exterior of the wall. The attachment system in this view is ideally suited for use with a ceramic window sill.

DETAILED DESCRIPTION

Wall panel attachment systems are provided herein. The wall panel attachment systems employ an extruded aluminum attachment system for fastening a plurality of panels to a building surface. The components may be fabricated from a milled or anodized aluminum. Each system's strength is enhanced by the use of an extruded perimeter frame design which carries the dead load for the various panels.

In the present disclosure, different types of panels are employed. These include aluminum composite material (ACM) panels, solar or photovoltaic (PV) panels, and porcelain ceramic tile (PCT) panels.

FIG. 1 presents a cross-sectional view of a wall panel attachment system 10, according to one embodiment. Here, the attachment system 10 is used to attach ACM panels 32 to the exterior surface of a wall 100.

The system 10 is designed to operate in accordance with the rainscreen principle. This means that the system 10 is designed so that a wall cavity formed under the individual panels is vented, resulting in a pressure-equalized system. Controlled moisture drainage within the system, coupled with this equalized pressure, contributes to effective, maintenance-free construction. The flow of air through a wall panel 32 and into a hollow interior 30 behind the ACM panel 32 is shown at arrows “A.”

The attachment system 10 may be fabricated through an extrusion process. The extrusion process begins with an aluminum billet, which is the material from which the profiles are preferably extruded. The billet must be softened by heat prior to the extrusion process. The heated billet is placed into an extrusion press, which represents a powerful hydraulic device wherein a ram pushes a dummy block. The dummy block, in turn, forces the softened metal through a precision opening, known as a die. The die produces the required shapes.

The extruded parts are cut to specific lengths. The extruded parts may have a milled or an anodized finish. It is, of course, understood that the system 10 is not limited by the specific extrusion process or other method by which the component parts are manufactured.

The system 10 includes a panel perimeter strip. FIG. 2 provides a cross-sectional view of an illustrative panel perimeter strip 14. FIG. 10 provides a cross-sectional view of a pair of panel perimeter strips 14. In FIG. 10, the panel perimeter strips 14 have been connected to corners of wall panels 32. Connection is by means of counter-sunk rivets 36. FIG. 10 will be discussed in further detail below.

Referring back to FIG. 1, three panel perimeter strips are seen, with one being marked as 14A. The panel perimeter strips 14/14A are attached to side surfaces of wall panels 32. The wall panels 32 are preferably fabricated from an aluminum composite material (ACM). Hollow rivets (numbered as 36 in FIG. 10) are also shown in FIG. 1, connecting the panel perimeter strips 14/14A to the panels 32.

The system 10 also includes an attachment clip 16. FIG. 3 provides a cross-sectional view of an illustrative attachment clip 16. The attachment clip 16 has a central fastening surface, and a pair of integrally formed wing members. Each wing member extends outwardly from the central fastening surface in a substantially symmetrical manner.

FIG. 10 provides another cross-sectional view of an attachment clip 16. In FIG. 10, each wing member of the attachment clip 16 is received by an opposing panel perimeter strip 14. Thus, the panel perimeter strips 14 are designed to mate together with the wing members of the attachment clips 16. The custom-designed extrusion allows for maximum attachment area without foregoing structural integrity.

The attachment clip 16 is used on-site to attach the panel perimeter strips 14 to a building. An exterior building surface is shown in FIG. 1 at 100. The exterior building surface 100 is above a building foundation or ground surface 110.

To install the panel system 10, sub-framing may be constructed. Preferably, the sub-framing comprises two back-to-back galvanized steel “L” angles, referred to sometimes herein as bracket assemblies. FIG. 12 is an enlarged cross-sectional view showing the system 10 of FIG. 1. In FIG. 12, two “L” angles are seen at 40. The L-angles 40 serve as brackets that allow the installer to level the substrate in all three axes before installation of panel assemblies 34. Preferably, stainless steel screws 44 are used to connect the L-brackets 40 to the building surface 100. Further, the L-brackets 40 themselves may be connected to each other through one or more stainless steel screws 46.

The bracket assemblies 40 are preferably installed horizontally at each horizontal joint. FIG. 11 shows a cut-away elevational view of the sub-framing, or L-brackets 40, as installed on an exterior building surface 100. It can be seen that a series of finished ACM panel assemblies 34 have been mounted onto the exterior building surface 100. Preferably, panel assemblies 34 are mounted from the bottom of the exterior building surface 100, and moves up. In this way, the installer may make sure that each row is level relative to the previous row installed. However, it is observed here that the finished panel assemblies 34 may beneficially be installed in any direction or sequence.

This aspect of the inventions deserves further discussion. As can be seen in FIG. 11, the L-angle brackets 40 have been placed along the exterior building surface 100 in horizontal rows. The finished panel assemblies 34 may be secured to the brackets 40 from left-to-right, from right-to-left, or even out of order provided the correct spacing is maintained. Similarly, the L-angle brackets 40 may be placed along the exterior building surface 100 in vertical rows. The finished panel assemblies 34 may then be secured to the brackets 40 from bottom-to-top, from top-to-bottom, or out of order provided the correct spacing is maintained.

Referring back to FIG. 12, a thin layer of isolation tape 42 may be applied to the back of the aluminum attachment clips 16. This prevents direct contact between the galvanized steel sub-framing (bracket assemblies 40) and the corresponding aluminum attachment clip 16. Thus, in turn, prevents galvanic action (electrolytic decay of the aluminum) over time. Preferably, stainless steel self-drilling screws 48 are used to fasten the aluminum attachment clips 16 to steel sub framing 40. After determining a logical order of installation, each panel assembly 34 is plumbed and leveled to ensure a tight and concise fit from panel to panel.

The individual panels 32 may optionally be supported by a panel stiffener. FIG. 4 provides a cross-sectional view of a panel stiffener 18, in one embodiment. In this embodiment, the panel stiffener 18 comprises a hollow tube having a square profile.

Such a panel stiffener 18 is desirable on large-sized panels. The panel stiffeners 18 may be used to prevent the popping or “oil canning” of the finished panel assemblies 34. As the individual panels 32 heat up, the panels 32 may expand and make a popping sound. The stiffeners 18 reinforce the panels 32 to reduce this effect.

FIGS. 19 and 20 provide cross-sectional views of panel stiffeners 18A, 18B, in alternate embodiments. In these arrangements, the panel stiffeners 18A, 18B are internally reinforced. This provides greater stability between the exterior building surface 100 and the panel assemblies 34.

Where panel stiffeners 18, 18A, 18B are used, the panel perimeter strip 14 may be adapted to better locate and secure the stiffener component. A panel perimeter strip 14A having a profile as shown in FIG. 18 may be advantageous for this purpose. An extended interior lip 15 of the panel perimeter strip 14A operates to secure the panel stiffener component.

Panel stiffeners may be provided in different sizes depending on the wind pressures to which the panels 34 will be exposed. A larger width panel stiffener 18B may be advantageous where there are greater wind loads on the attachment system 10 or if less deflection on the individual panels 34 is desired. It will be appreciated that the construction of the panels 32 themselves also provides a basic level of rigidity, and stiffeners are not necessarily required.

The attachment system 10 also includes an infill strip. An infill strip 38 is shown in the cross-sectional views of FIGS. 1, 10, and 12. An infill strip 38 is also shown in cross-sectional isolation in FIG. 9. The infill strip is preferably cut to a width of approximately 1¼″ (32 mm) for a ½ (13 mm) joint. The infill strip 38 replaces the conventional caulk joint, giving the panel system a clean, maintenance free appearance. The infill strip 38 also is used to hide the fasteners 48 for the attachment clip 16.

Each attachment clips 16 is designed so as to interlock with a pair of panel perimeter strips 14 while holding an infill strip 38 securely in place.

Both the infill strips 38 and the panels 32 are preferably fabricated from an aluminum composite material (“ACM”). FIGS. 5 through 7 present illustrative cross-sectional views of an ACM panel 32 undergoing fabrication. The panel 32 may be fabricated from several layers as described below.

As shown in FIG. 5, ACM 20 consists of a core of low density polyethylene 24 sandwiched between two sheets of aluminum 22 (each approximately 0.5 mm thick). The finish face of the aluminum sheets 22 is coated with a polyvinylidene fluoride coating. The inner aluminum layer is typically coated with chrome or polyester coatings. The standard thickness of the panel 32 is 5/32″ (4 mm) but thickness may range from ⅛″ (3 mm) to ¼″ (6 mm), depending on customer preference or structural requirements.

A finished ACM panel 32 may be fabricated from a flat sheet of ACM 26 using different types of router and cutting bits 28 (seen in FIG. 6). After the sheet of ACM 26 has been cut and routed, the sheet 26 is then bent along the router lines to form the finished panel 32 (seen in FIG. 7). The newly-shaped panel 32 is then assembled with the panel perimeter strip 14 using a panel rivet 36 to complete the finished panel assembly (seen in FIGS. 8 and 10). A standard panel rivet for this application may be 3/16″ diameter.

FIG. 8 shows a finished panel assembly 34. Panel perimeter strips 14 are shown supporting a panel 32. Two rivets 36 are also shown, preserving through-openings through the panel perimeter strips 14 and connected panels 32.

There are various methods to accomplish the routing and cutting process:

Method 1

Handheld router (not shown): A handheld router is used more often when reworking a panel to a different size. This method requires the simplest tool set up, but is the most labor-intensive method of fabrication due to the lengthy time for setup and layout of each different panel.

Method 2

Vertical table saw (not shown): A vertical table saw can also be used, both to cut and rout the panels. Custom “V” routing blades can be purchased to rout the panels. Panel design is limited using the vertical table saw in itself. Using it in combination with the hand held router has its advantages, but it is still a costly way to manufacture panels.

Method 3

CNC-Machine (not shown): The computer numerically controlled (CNC) machine is a complete and concise way to manufacture panels. Once the panel has been designed by a CAD operator it is then sent directly to the machine. This machine has been found to be very useful and economical for manufacturing panels. This is the applicants' preferred method for cutting and routing panels.

FIGS. 13 through 16 demonstrate the installation of an infill strip 38 into an attachment system 10. The infill strips 38 are preferably shipped to a construction site in long lengths, and are cut to fit on-site. The strips 38 may have a protective plastic coating, which is then removed from the face of the infill strips 38 before installation.

The infill strips 38 may be installed one of two ways:

First, as shown in FIGS. 13 through 15, individual infill strips 38 may be slipped into a slot 37 before the adjacent panel is installed. This is of benefit when the edge of the joint is not accessible, or when the infill strip 38 has a curve or bend in it. The infill strip 38 is fitted into the space between the panel 32 and the attachment clip 16 as illustrated in FIG. 13 and FIG. 14. Then, an adjacent panel 32′ is installed so that the infill strip 38 and attachment clip 16 engage into the slots 37 in the panel edge at the perimeter strip 14A′ (FIG. 15).

Second, and as an alternative method of installation, the installer can slide the infill strip 38 in from the end. This is shown in FIG. 16. This allows for a simplified installation of the finished panels 34. The infill strips 38 are not installed until an area is complete. This means that panel assemblies 34 can be adjusted for straightness and position even after adjacent panels have been installed. The difficulty with this method is that the end of the joint will not always be accessible (i.e. wall or window frame) and the infill strip 38 may have a tendency to catch on the attachment clips 16 as it is being slid into the joint. To aid in the sliding of the strips 38, a tool may be used to pull the leading edge of the strips 38 over the clips (not shown in FIG. 16).

FIG. 17 presents a perspective view of a finished wall panel exterior. The finish faces of the panels 32 may have a protective film 50 to protect against minor abrasions that may occur during handling and installation. The protective film 50 may be peeled back from the returns of the panels 32 before installing. To keep the panels 32 clean and free of construction debris, generally the protective plastic film 50 is only removed from the faces of the panels once the landscaping has been completed.

As can be seen, a dry joint aluminum wall panel attachment system 10 for attaching wall panels to an exterior building wall is provided. The attachment system includes a plurality of individual aluminum-based wall panels 32. Each wall panel has an exterior flat surface and four side surfaces. At least two of the side surfaces are bent generally perpendicularly to the exterior flat surface. In this way, a hollow interior portion 30 is defined.

The attachment system 10 also includes a plurality of bracket assemblies. Each bracket assembly is configured to be fastened to the exterior wall 100. In one aspect, each bracket assembly comprises two back-to-back L-angle brackets 40 fastened to each other via connectors 46 to form a generally Z-shaped assembly. A first end is for attachment to the exterior wall surface 100, and a second end is for fastening to an attachment clip 16. Preferably, the bracket assemblies 40 are fabricated from steel for strength.

The attachment system 10 also has a plurality of attachment clips 16. Each clip 16 is preferably fabricated from aluminum and is configured to be fastened to a respective bracket assembly by a fastener 48. Preferably, each fastener 48 comprises a threaded fastener. The attachment clips 16 carry the dead load of the wall panels 32.

Each attachment clip 16 has a pair of integrally formed wing members. Each wing member extends outwardly from the central fastening surface in a substantially symmetrical manner. Preferably, isolation tape 42 is applied between the attachment clips 16 and the respective bracket assemblies.

The attachment system 10 also includes a plurality of panel perimeter strips 14. Preferably, each panel perimeter strip 14 is fabricated from aluminum. Each panel perimeter strip 14 (or, optionally, 14A) is configured to be fastened to one side surface of a respective wall panel 32. Further, each panel perimeter strip 14 comprises a generally C-shaped member configured to reside inside of and extend along an inside portion of a side surface of a respective wall panel 32, and a receiving member integrally attached to the C-shaped member configured to extend beyond the side surface of a wall panel 32 and provide a slot 37 adapted to engage and interlock one of the wing members of the attachment clip 16, thus operatively connecting a respective wall panel assembly 34 to the attachment clip 16 and thereby to the wall 100.

The attachment system 10 also includes rivets 36. The rivets 36 are placed along the side surface of the wall panels 32 to connect the side surface of a respective wall panel 32 to a receiving member of a panel perimeter strip 14. The rivets 36 are hollow to permit the ingress and egress of air and moisture through the hollow interior area 30 behind the panels 32.

The attachment system 10 further includes a plurality of infill strips 38. Each infill strip 38 is preferably fabricated from a substantially rigid material comprising aluminum or aluminum composite material. Each of the infill strips 38 is non-sealingly disposed within respective slots 37 of adjoining panel perimeter strips 14.

The infill strips 38 are placed between a corresponding attachment clip 16 and the one or more rivets 36 so as to cover the fasteners 48. In one aspect, each infill strip 38 is engaged with the slot 37 of a panel perimeter strip prior to installing an adjacent wall panel assembly 34. Alternatively, each infill strip 38 may be introduced to the slots 37 of two adjacent panel perimeter strips 32 after two adjacent wall panel assemblies 34 have been installed.

The attachment system 10 is held together non-adhesively. In addition, the attachment system 10 is configured to allow panel assemblies 34 to be secured to respective panel attachment clips 16 in any sequence.

The wall panel attachment system 10 may be modified for use with stiff or rigid panels. In this instance, an adhesive is applied to a flat surface of a tile perimeter strip. The rigid panels may be, for example, fabricated from ceramic.

In one embodiment, it is desirable to integrate the wall panel attachment system 10 with the ability to generate clean energy for the building on which the wall panels are mounted. FIG. 21 provides a cross-sectional view of a photovoltaic (PV) wall panel attachment system 60. The system 60 may be used to attach multiple PV wall panels 61 to an exterior building wall (such as wall 100 of FIG. 1) adjacent to ACM panels. The system 60 includes a plurality of PV wall panels 61 which are attached to a structural sub-assembly, as will be described below.

First, bracket assembly 62 is mounted to the exterior building wall 100. The bracket assembly 62 may comprise one or more L-angle brackets, and can be configured to accommodate adjacent panels, as needed. For example, as shown in FIG. 21, an installed aluminum composite wall panel 32 is shown residing above or adjacent an installed PV panel 61. The bracket assembly 62 may be constructed of multiple bracket components affixed to one another to form a unitary structural foundation or sub-framing for the remainder of the system 60.

The bracket assembly 62 shown in FIG. 21 comprises a primary base bracket 71, a secondary base bracket 72, and a panel mounting bracket 73, all of which are secured to one another by conventional fasteners, such as stainless steel screws 46. The primary base bracket 71 and the secondary base bracket 72 are each secured to the exterior building wall 100 by fasteners 63, which are preferably masonry screws. Optionally, a cable guide 64 is attached to the bracket assembly 62 to permit secure routing of electrical cables 67 extending from each of the PV wall panels 61. The cables 67 carry electric current generated by the PV panels 61.

The wall panel attachment system 60 also includes attachment clips 16. The attachment clips 16 are configured to be fastened to respective bracket assemblies 62 by a fastener 68 and to carry the dead loads of the respective PV wall panels 61. The attachment clips 16 may have a single-wing design as shown in FIG. 21, or a double-wing design as shown in FIG. 21, depending on the location along the wall 100 in which they are used.

FIG. 26 shows a series of cross-sectional views of attachment clips that may be used in the attachment system 60. A double-wing design is shown at 16. The double-wing design is used when multiple solar (or other stiff) panels 61 are being hung adjacent to one another. The double-wing clips 16 allow panels 61 to be hung in any sequence.

A single-wing design is shown at 16A. This is actually the attachment clip used in FIG. 21. The single-wing design 16A may be utilized when a panel 61 is being installed at an edge of a wall or adjacent a window sill. The single-wing design 16A may also be utilized when a panel 61 is being installed adjacent an ACM panel 32, as shown in FIG. 21.

The wall panel attachment system 60 also includes a plurality of tile perimeter strips 74. The tile perimeter strips 74 provide lateral support for the PV wall panels 61. The tile perimeter strips 74 may be placed along horizontal edges of the panels 61, vertical edges of the panels 61, or both. Further, where the panels 61 are polygonal bodies having edges that are offset from vertical and horizontal, the tile perimeter strips 74 may be angled to support the offset edges.

Each tile perimeter strip 74 comprises a generally C-shaped member configured to extend along a rear surface 69 of a respective PV wall panel 61. Each tile perimeter strip 74 also includes a receiving member integrally attached to the C-shaped member having a slot adapted to engage and interlock one of the wing members of the attachment clip 16, shown best in the enlarged views of FIGS. 22 and 23.

FIG. 27 shows a series of cross-sectional views of panel perimeter strips that may be used with the attachment system 60. The panel perimeter strip 74 shown in FIG. 27 is also used in FIG. 21. The tile perimeter strips 74 provide horizontal support for the PV wall panels 61.

The wall panel attachment system 60 may further include one or more panel stiffeners 18. As shown in FIG. 21, a panel stiffener 18 may be placed in the C-shaped member of the panel perimeter strip 74 to provide lateral support for an adjacent panel 61. Each panel stiffener 18 is fixed between the C-shaped members of opposing tile perimeter strips 74, as shown in FIGS. 22 and 23. Preferably, the panel stiffeners 18 are connected to the tile perimeter strips 74 using conventional fasteners 75, and are positioned such that the left and right edges of the PV wall panel 61 are substantially flush with the panel stiffeners 18.

It is noted that in the views of FIGS. 21, 22, and 23, a gap is present between the panel 61 and the stiffener 18. In reality, this gap is very small, such as only 1 to 7 mm. Therefore, the panels 61 and the stiffeners 18 may be considered to be “attached.”

Each PV wall panel 61 is attached to the panel stiffeners 18 and to the tile perimeter strips 74. Preferably, the PV wall panel 61 is bonded to the panel perimeter strips 74 using a structural silicone adhesive 66. An example of a suitable adhesive 66 is the 983 Silicone Glazing and Curtainwall adhesive/sealant product manufactured by Dow Corning.

In a preferred embodiment, a high-density closed-cell foam tape 65 is applied to either a rear perimeter surface 69 of the PV wall panel 61, or to the tile perimeter strip 74. The ¼″ wide by ⅜″ high, high-density, closed-cell foam tape 65 provides spacing for the necessary thickness of the structural silicone adhesive 66, as shown in FIG. 24.

In operation, the high-density closed-cell foam tape 65 may first be applied to the planar surface of a panel perimeter strip 74. Thereafter, a PV wall panel 61 is held onto or laid on the panel perimeter strip 74 and, optionally, a panel stiffener 18. A bead or volume of structural silicone adhesive 66 is then applied to a void formed between the PV wall panel 61 and tile perimeter strip 74 outside of the foam tape 65. The void is filled until the structural silicone adhesive 66 is flush with the exterior perimeter edges of the tile perimeter strip 74 and the panel 61, as shown is FIGS. 22 and 23. The high-density, closed-cell foam tape 65 confines the structural silicone adhesive 66 to the tile perimeter strip 74. The tape 65 also maintains a gap between the panel perimeter strip 74 and the panel 61 to ensure that that the electrically active area on the PV wall panel 61 remains unaffected.

Structural bonding tape can be used as an alternative to the structural silicone adhesive 66 and the foam tape 65 when utilizing tile perimeter strip 74D. One such suitable bonding tape is the VBH bonding tape manufactured by 3M Company. Preferably, an additional adhesive 66 is applied to the rear surface periphery of the PV wall panel 61 in the form of a structural silicone adhesive and sealant, such as the 983 Silicone Glazing and Curtainwall adhesive/sealant product manufactured by Dow Corning. In this manner, the PV wall panel 61 is securely bonded to the structural assembly beneath it.

The PV wall panels 61 may be any desired PV panel that is suitable for use in the desired application. One example of such a PV panel is the ASI OPAK solar panel manufactured by Schott North America, Inc., of Elmsford, N.Y.. It is noted that such solar panels can be very heavy—even up to 60 pounds, depending on dimensions. Therefore, care should be taken to ensure that a quality adhesive is used for securing the panels 61 to the panel perimeter strips 74.

It will be understood to those of ordinary skill that the shape and dimensions of the mounting components described above should permit mounting of the PV wall panels 61 so that their exterior surfaces may be flush with the adjacent non-solar wall panels 32. Thus, in FIG. 21, a solar wall panel 61 is placed on an exterior wall 100 adjacent a non-PV wall panel, e.g., the ACM panel 32.

It is also understood that the panel systems 60 herein may also be used with solar wall panels being adjacent to one another. FIG. 25 is a top view of another photovoltaic (PV) wall attachment system 60. Here, two solar wall panels 61 are placed on an exterior wall 100 adjacent to one another. An attachment clip 16 having a central fastening member and two symmetrically extending wing members is provided. Further, two tile perimeter strips 74 are provided. The tile perimeter strips 74 are adhesively connected to the rear surfaces of the respective solar panels 61 using adhesive 66.

Through-openings may optionally be provided in the tile perimeter strips 74. These are shown in FIG. 25 at 77. The through-openings 77 permit the ingress and egress of air and moisture behind the solar wall panels 61 to provide a pressure-balanced and moisture-drained environment.

The description above for FIGS. 22 through 25 pertain to the use of solar wall panels with an attachment system 60. The attachment system 60 allows for the installation of PV panels 61 wherein panel assemblies (panels 61 with panel perimeter strips 74) may be hung in any sequence. It is noted that modifications of certain components to the attachment systems 60 may be made. These include the attachment clip 16, the panel perimeter strip 74, and the infill strip 38.

FIG. 26 shows a series of cross-sectional views of attachment clips that may be used in the attachment system 60. The first attachment clip 16 is the attachment clip shown in FIG. 3. The attachment clip is also shown in the attachment system of FIG. 25. The second attachment clip 16A is the attachment clip shown in the attachment system of FIG. 21. This attachment clip 16A is also seen at the bottom of FIG. 1.

It is understood that where panels 61 are placed along a corner or edge of a wall, some modification of the attachment clip 16 is necessary. The half-clip of 16A is noted above. Additional attachment clips 16B and 16C are shown. Attachment clip 16B is illustratively shown being used in FIG. 33, while attachment clip 16C is illustratively shown being used in FIG. 34. Attachment clips 16B and 16C are useful where panels 61 are being installed along a corner or edge of a wall or adjacent a door frame or window sill.

FIG. 27 shows a series of cross-sectional views of panel perimeter strips that may be used with the attachment system 60. The first panel perimeter strip 74 is the panel perimeter strip shown in the attachment systems of FIGS. 21 and 25. However, modifications to the panel perimeter strip 74 are shown at 74A, 74B, 74C, and 74D. These alternate embodiments may be used to provide additional structural security to the PV panels. For example, the panel perimeter strip 74D may be used where the installer uses structural bonding tape in lieu of the structural silicone adhesive 66.

The various panel perimeter strips 74, 74A, 74B, 74C, 74D may be used to secure stiff panels or tiles to exterior surface of a building. In this instance, the perimeter strips may be referred to as tile perimeter strips.

FIG. 28 provides a series of cross-sectional views of infill strips as may be used in the attachment system 60. Infill strip 38 is the infill strip shown in FIG. 9. This infill strip is also seen in the attachment system of FIG. 15. However, modifications to the infill strip may be made where a different profile for a panel perimeter strip is employed. Alternate infill strip profiles are shown at 38Ai, 38Aii, 38B, and 38C.

Infill strips 38Ai and 38Aii are used when access and removal panels are required. Infill strip 38B is used when the panel revealed joint is filled—to various depths or widths—utilizing the slots created by the tile perimeter strip 74 and the attachment clips 16. Infill strip 38C is used when the panel revealed joint is desired to be enclosed, utilizing the two adjoining tile perimeter strips 74 only.

The description above for FIGS. 1, 12, 21 and 25 relate to a wall panel attachment system that may be used for the installation of ACM 32 and solar 61 wall panels, and combinations thereof. However, the wall panel attachment systems described above may be used with rigid, non-solar wall panels.

FIG. 29 provides a perspective view of a flat panel 90 that may be fastened or adhered to perimeter strips and panel stiffeners. The illustrative panel 90 is fabricated from a ceramic material. For purposes of the present disclosure, the terms “ceramic” or “ceramic material” may include oxides such as alumina and zirconia. Specific examples include bismuth strontium calcium copper oxide, silicon aluminium oxynitrides, uranium oxide, yttrium barium copper oxide, zinc oxide, and zirconium dioxide. “Ceramic” may also include non-oxides such as carbides, borides, nitrides and silicides. Specific examples include titanium carbide, silicon carbide, boron nitride, magnesium diboride, and silicon nitride. The term “ceramic” also includes composites, meaning particulate reinforced, combinations of oxides and non-oxides. Additional specific examples of ceramics include barium titanate, strontium titanate, ferrite, and lead zierconate titanate.

A wall panel attachment system 80 is offered herein, wherein the panels are fabricated from ceramic. A preferred ceramic material is porcelain. Porcelain is a ceramic material made by heating raw materials, generally including clay in the form of kaolin, in a kiln to temperatures between 1,200° C. (2,192° F.) and 1,400° C. (2,552° F.). Porcelain may be fabricated as tiles, referred to as porcelain ceramic tile, or PCT. In this instance, PCT may also be referred to herein as a “cladding material.”

FIG. 30 is a top (or, alternatively, a side) cross-sectional view of a porcelain ceramic tile (PCT) wall panel attachment system 80, in one embodiment. Here, two porcelain ceramic wall panels 81 are placed on an exterior wall 100 adjacent to one another.

In the attachment systems 80 of FIG. 30, a plurality of ceramic tiles 81 may be installed onto a wall in any sequence. However, it is noted that the system 80 of FIG. 30 is essentially the same as the system 60 shown in FIG. 25, but without the electrical cables 67, and wherein the panels are ceramic rather than solar wall panels.

Each ceramic tile, or panel 81, may be 2.5 mm to 3.00 mm in width. Each panel 81 may further be reinforced using a 0.5 mm to 1.0 mm laminate of fiberglass on one side, and a 0.5 mm to 1.0 mm laminate of fiberglass on the opposing side.

As with the photovoltaic (PV) wall panel attachment system 60, the PCT attachment system 80 utilizes a bracket assembly 62 to support the panel 81. The bracket assembly 62 is mounted to the exterior building wall 100. The bracket assembly 62 may comprise one or more L-angle brackets 72, 73, and can be configured to accommodate adjacent panels, as needed. The brackets 72, 73 may be two back-to-back galvanized steel “L” angles. The bracket assembly 62 may be constructed of multiple bracket components affixed to one another to form a unitary structural foundation or sub-framing for the remainder of the system 80.

The bracket assembly 62 shown in FIG. 30 comprises a wall bracket 72 and a panel mounting bracket 73. These brackets 72, 73 are secured to one another by conventional fasteners, such as stainless steel screws 46. The L-angle brackets 72, 73 serve as brackets that allow the installer to level the substrate in three axes before installation of PCT panels 81. The sub-framing installation may be the same as for the ACM panels 32.

Attachment clips 16 are configured to be fastened to respective panel attachment systems 80 by a fastener 68 and to carry the dead loads of the respective PCT wall panels 81. The attachment clip 16 shown in FIG. 30 uses a double-wing design. Tile perimeter strips 74 are also shown in FIG. 30, attached to the ceramic panels 81. The perimeter strips 74 include a through-opening 77. The through-opening permits the ingress and egress of air and moisture behind the ceramic wall panel 81 to provide a pressure-balanced and moisture-drained environment. However, the hollow rivets 36 from ACM system 10 are not needed.

The PCT wall panel attachment system 80 also includes a high-density, closed-cell foam tape 85. The tape 85 is, and acts in the same manner as, the foam tape 65 as shown in FIG. 25. The tape 85 may be applied to either the rear perimeter surface 89 of the PCT wall panel 81 or to the planar surface of the tile perimeter strip 74. The high-density, closed-cell foam tape 85 creates spacing for the necessary thickness needed for the adhesive 86. This, again, is in the form of a structural silicone adhesive and sealant, such as the 983 Silicone Glazing and Curtainwall adhesive/sealant product manufactured by Dow Corning. In this manner, the PCT wall panel 81 is securely bonded to the structural assembly beneath it. The foam tape 85 also acts as a backstop as silicone adhesive is squeezed into the gap between the panel perimeter strip 74 and a rear surface 89 of the ceramic panel 81. This assembly process is essentially identical to that of the PV wall panel attachment system 60.

It is noted that in most cases, the use of the peripheral structural silicone adhesive 66 is adequate. For some panels, the operator may choose to add a bonding tape (shown at 95 in FIG. 33). For larger panels, the operator may further add structural silicone adhesive 86 in the gap between the stiffeners 18 and the rear 89 of the panels 81. Also, structural bonding tape may be used as an alternative to the silicone adhesive 86 and the high-density closed foam tape 85 when utilizing tile perimeter strip 74A.

FIG. 31 provides a cross-sectional view of a wall panel assembly 84. The assembly 84 utilizes a porcelain ceramic tile (PCT) wall panel 81 attached to panel perimeter strips 74. The assembly 84 is ready for hanging as part of the system 80 of FIG. 30.

FIGS. 30 and 31 demonstrate the use of porcelain ceramic tile (PCT), as a cladding material that can be integrated in a wall panel attachment system 80. The attachment system 80 allows individual panels to be hung on the exterior wall of a building in any sequence. The attachment system 80 is generally used for placing tiles in the center portion of a wall, as indicated with panel assemblies 34 in FIG. 11. Where placing panel assemblies along an edge, corner, or window, a modification is made to the attachment clip, as shown below in FIGS. 32, 33 and 34.

FIG. 32 is a cross-sectional view of a PCT wall panel attachment system 80′ at an end of a wall 100. A porcelain ceramic tile 81 is shown placed along the exterior of the wall 100. Flashing is indicated at 92 at the end of the wall 100. The attachment system 80′ is ideally suited for use with a curtain wall sill (not shown).

The attachment system 80′ uses several of the same items as the photovoltaic (PV) wall attachment system 60 of FIG. 21. In this respect, the PCT attachment system 80′ includes a bracket assembly 62. The bracket assembly 62 may comprise one or more L-angle brackets. Here, the bracket assembly 62 comprises a wall bracket 72 and a panel mounting bracket 73. The brackets 72, 73 are affixed to one another by connector screws 46 to form a unitary structural foundation or sub-framing for the remainder of the system 81′.

The wall bracket 72 and the panel mounting bracket 73 are each secured to the exterior building wall 100 by one or more fasteners 63. Fastener 63 seen in FIG. 32 is preferably a masonry screw.

The PCT wall panel attachment system 80′ utilizes an attachment clip and a panel perimeter strip. The attachment clip is the attachment clip 16A from FIG. 26, while the panel perimeter strip is the panel perimeter strip 74 from FIG. 27. It can be seen that the panel perimeter strip 74 includes a through-opening 77. The through-opening permits the ingress and egress of air and moisture behind the ceramic wall panel 81 to provide a pressure-balanced and moisture-drained environment.

The PCT wall panel attachment system 80′ also includes a closed-cell foam tape 85, such as neoprene. The tape is 85 is applied to the rear perimeter surface 89 of the PCT wall panel 81 to create spacing. The PCT wall panel attachment system 80′ further includes an additional adhesive 86 applied to the rear surface periphery 89 of the PCT wall panel 81. This, again, is in the form of a structural silicone adhesive and sealant, such as the 983 Silicone Glazing and Curtainwall adhesive/sealant product manufactured by Dow Corning. In this manner, the PCT wall panel 81 is securely bonded to the structural assembly beneath it.

FIG. 33 is a cross-sectional view of a PCT wall panel attachment system 80″ at an end of a wall 100, in yet another alternate embodiment. A porcelain ceramic tile 81 is again shown placed along the exterior of the wall 100. The attachment system 80″ is ideally suited for use with a curtain wall head (not shown).

The PCT attachment system 80″ also includes the wall mounting brackets 72, 73, the one or more fasteners 63, and the connector screws 46. The PCT wall panel attachment system 80″ also utilizes an attachment clip and a panel perimeter strip. The attachment clip is the attachment clip 16B from FIG. 26, while the panel perimeter strip is the tile perimeter strip 74A from FIG. 27. The tile perimeter strip 74A includes the through-opening 77 to permit the ingress and egress of air and moisture behind the ceramic wall panel 81.

The PCT attachment system 80″ shown in FIG. 33 does not use tape 85 and structural silicone adhesive 86; instead, an optional thin sheet 94 is placed along the outside flat surface of the tile perimeter strip 74A. The sheet is fabricated from anodized aluminum or other metallic material. The sheet 94 may be, for example, pre-painted galvanized steel. The sheet 94 is secured to the perimeter strip 74A by counter-sunk rivets (not shown). Strips of bonding tape 95 are then placed between the sheet 94 and the ceramic tile 81 in order to adhere the ceramic tile 81 to the attachment system 80″.

The use of the sheet steel 94 is particularly beneficial when the tiles 81 are large, such as greater than 25 square feet in area. The sheet steel 94 is “picture framed” along and within the perimeter strip 74A, and provides back support for the ceramic tiles 81. This, in turn, prevents the tile 81 from shattering in the unlikely (but nevertheless possible) event that some object strikes the tile 81 after the attachment system has been installed on the side of a building, and breaks the tile 81.

FIG. 34 is still another cross-sectional view of a PCT wall panel attachment system 80′″ at an end of a wall 100, in an alternate embodiment. A porcelain ceramic tile 81 is again shown placed along the exterior of the wall 100. The attachment system 80′″ is ideally suited for abutment with a ceramic window sill (not shown).

The PCT attachment system 80′″ also includes the wall mounting bracket 72. Tape 85 and adhesive 86 are also employed. The PCT wall panel attachment system 80″′ also utilizes an attachment clip and a panel perimeter strip. The attachment clip is the attachment clip 16C from FIG. 26, while the panel perimeter strip is the panel perimeter strip 74 from FIG. 27. The panel perimeter strip 74 need not include the through-opening 77.

As can be seen, different attachment clips 16A, 16B, 16C are used in FIGS. 32, 33, and 34. Each of these attachment clips 16A, 16B, 16C is configured to be fastened to respective panel attachment systems 80′, 80″, 80′″ by a fastener 68 and to carry the dead loads of the respective PCT wall panels 81.

The foregoing description illustrates only certain preferred embodiments of the invention. The invention is not limited to the foregoing examples. That is, persons skilled in the art will appreciate and understand that modifications and variations are, or will be, possible to utilize and carry out the teachings of the invention described herein. Accordingly, all suitable modifications, variations and equivalents may be resorted to, and such modifications, variations and equivalents are intended to fall within the scope of the invention as described and within the scope of the claims.

Claims

1. A wall panel system for attaching multiple wall panels to an exterior building wall, each wall panel having a dead load, and the system comprising:

a plurality of rigid wall panels;

a plurality of bracket assemblies configured to be fastened to the exterior wall;

a plurality of attachment clips configured to be fastened to respective bracket assemblies by a fastener and to carry the dead loads of the respective wall panels, each attachment clip having a central fastening surface fastened to the bracket assembly and a pair of integrally formed wing members extending outwardly from the central fastening surface;

a plurality of tile perimeter strips configured to reside along a rear surface of a respective wall panel, each tile perimeter strip comprising: a generally C-shaped member having a planar surface configured to reside along a rear surface of a respective wall panel, and a receiving member integrally attached to the C-shaped member and having a slot adapted to engage and interlock one of the wing members of the attachment clip, thus operatively connecting a respective wall panel to the attachment clip and, thereby, to the wall; wherein the system is configured to allow wall panels to be secured to respective bracket assemblies in any sequence.

2. The attachment system of claim 1, wherein each panel comprises a plurality of photovoltaic cells for converting solar energy to electrical energy.

3. The attachment system of claim 2, wherein each panel further comprises:

a substantially flat exterior surface; and

an electrical cable for delivering electrical current from the plurality of photovoltaic cells.

4. The attachment system of claim 1, wherein each panel is fabricated from a ceramic material.

5. The attachment system of claim 4, wherein:

each panel further comprises a substantially flat exterior surface; and

each panel is fabricated from a porcelain material to form a porcelain ceramic tile.

6. The attachment system of claim 4, further comprising:

a plurality of thin metallic sheets placed along and connected to the planar surface of the panel perimeter strips, wherein each of the plurality of ceramic panels is adhesively connected to a corresponding metallic sheet.

7. The attachment system of claim 1, wherein:

each bracket assembly comprises two back-to-back L-angle brackets fastened to each other to form a generally Z shaped assembly, a first end of which is for attachment to the wall and a second end of which is for fastening to an attachment clip; and

the pairs of wing members of the attachment clips extends outwardly from the central fastening surface in a substantially symmetrical manner.

8. The attachment system of claim 1, wherein each C-shaped member further comprises a through-opening to permit the ingress and egress of air and moisture behind the rigid wall panels to provide a pressure-balanced and moisture-drained environment.

9. The attachment system of claim 1, further comprising:

a plurality of infill strips non-sealingly disposed within respective slots of the tile perimeter strips so as to cover the fastener, each infill strip being fabricated from a substantially rigid material comprising aluminum, aluminum and polyethylene, polyvinyl chloride (PVC), or combinations thereof.

10. The attachment system of claim 1, wherein each fastener comprises a threaded fastener.

11. The attachment system of claim 1, wherein each panel perimeter strip is pre-adhered to a wall panel before installation to the building wall.

12. The attachment system of claim 1, further comprising:

an isolation tape applied between each attachment clip and a corresponding bracket assembly.

13. The attachment system of claim 1, wherein:

each attachment clip comprises aluminum; and

each bracket assembly comprises steel.

14. The attachment system of claim 1, wherein each tile perimeter strip is fabricated at least partially from anodized aluminum.

15. The attachment system of claim 1, further comprising:

a panel stiffener placed between opposing tile perimeter strips along the rear surface of each wall panel to reinforce each wall panel.

16. The attachment system of claim 1, further comprising:

an adhesive applied to the rear surface of each wall panel and adhered to each tile perimeter strip along the planar surface, wherein the adhesive comprises structural silicone adhesive, bonding tape, or combinations thereof.

17. The attachment system of claim 16, wherein:

the adhesive is a structural silicone adhesive applied to the rear surface of each wall panel; and

the adhesive on each rear surface resides adjacent a strip of foam tape.

18. A photovoltaic (PV) wall panel system for attaching multiple PV wall panels to an exterior building wall, each PV wall panel having a dead load, and the system comprising:

a plurality of PV wall panels, each PV wall panel comprising a plurality of photovoltaic cells for converting solar energy to electrical energy;

a plurality of bracket assemblies configured to be fastened to the exterior building wall;

a plurality of attachment clips configured to be fastened to respective bracket assemblies by a fastener and to carry the dead loads of the respective PV wall panels, each attachment clip having a central fastening surface fastened to the bracket assembly and at least one integrally formed wing member, each wing member extending from the central fastening surface;

a plurality of tile perimeter strips, each tile perimeter strip comprising: a generally C-shaped member having a planar surface configured to reside along a rear surface of a respective PV wall panel, and a receiving member integrally attached to the C-shaped member having a slot adapted to engage and interlock one of the wing members of the attachment clip; and

an adhesive for connecting the wall panels to the planar surfaces of the C-shaped members at least along selected edges; and

wherein the system is configured to allow the PV wall panels to be secured to respective bracket assemblies in any sequence.

19. The attachment system of claim 18, further comprising:

one or more cable guides attached to each bracket assembly, wherein each of the cable guides is configured to receive electrical cables extending from the rear surface of the PV wall panels for delivering electrical current from the plurality of photovoltaic cells.

20. The attachment system of claim 18, further comprising:

at least one panel stiffener fixed between the C-shaped members of opposing tile perimeter strips to provide support for each PV wall panel along the rear surface.

21. The attachment system of claim 18, wherein the adhesive comprises structural silicone adhesive, strips of bonding tape, or combinations thereof.

22. The attachment system of claim 18, wherein:

the adhesive is a structural silicone adhesive applied to the rear surface of each wall panel; and

the adhesive on each rear surface resides adjacent a strip of foam tape.

23. A hybrid wall panel system for attaching multiple wall panels to an exterior building wall, each wall panel having a dead load, and the system comprising:

a plurality of bracket assemblies configured to be fastened to the exterior wall;

a plurality of attachment clips configured to be fastened to respective bracket assemblies by a fastener and to carry the dead loads of the respective wall panels, each attachment clip having a central fastening surface fastened to the bracket assembly and a pair of integrally formed wing members, each wing member extending from the central fastening surface;

a plurality of solar wall panels, each solar wall panel having a plurality of photovoltaic cells for converting solar energy to electrical energy;

a plurality of tile perimeter strips configured to be adhesively connected to a rear surface of a respective solar wall panel, each tile perimeter strip comprising: a generally C-shaped member having a planar surface configured to reside along a rear surface of a respective wall panel, and a receiving member integrally attached to the C-shaped member and having a slot adapted to engage and interlock one of the wing members of the attachment clip, thus operatively connecting a respective wall panel to the attachment clip and, thereby, to the wall;

an adhesive for connecting the solar wall panels to the planar surfaces of the C-shaped members at least along selected edges;

a plurality of non-PV wall panels, each non-PV wall panel having an exterior flat surface and at least two side surfaces bent generally perpendicularly to the exterior flat surface and defining a hollow interior portion;

a plurality of panel perimeter strips configured to be fastened to one side surface of a respective non-PV wall panel, each panel perimeter strip comprising: a generally C-shaped member configured to extend reside inside of and reside along an inside portion of a side surface of a respective wall panel, and a receiving member integrally attached to the C-shaped member configured to extend beyond the side surface of a wall panel and having a slot adapted to engage and interlock one of the wing members of the attachment clip, thus operatively connecting a respective wall panel to the attachment clip and, thereby, to the wall;

one or more rivets provided along the side surface of respective non-PV wall panels to connect the side surface to the receiving member of a respective panel perimeter strip;

wherein: the hybrid system is configured to allow non-PV wall panels to be secured to respective bracket assemblies in any sequence; at least one solar wall panel is adjacent to at least one non-PV wall panel; and the tile perimeter strips and the panel perimeter strips are dimensioned and configured such that the exterior surfaces of the solar wall panels and the non-PV wall panels are substantially flush with one another.

24. The attachment system of claim 23, further comprising:

at least one panel stiffener fixed between the C-shaped members of opposing tile perimeter strips to provide support for each PV wall panel along the rear surface.

25. The attachment system of claim 23, wherein the adhesive comprises structural silicone adhesive, bonding tape, or combinations thereof.

26. The attachment system of claim 23, wherein:

the adhesive is a structural silicone adhesive applied to the rear surface of each wall panel; and

the adhesive on each rear surface resides adjacent a strip of foam tape.

27. The attachment system of claim 23, wherein the system is configured to allow the solar wall panels to be secured to respective bracket assemblies in any sequence.