WALL PANEL SYSTEMS, WALL PANEL ATTACHMENT APPARATUSES AND MOUNTING BRACKETS FOR WALL PANELS, AND RELATED METHODS

Abstract

The present subject matter relates to wall panel systems, attachment apparatuses and mounting brackets for wall panels and related methods. In particular, the present subject matter relates to wall panel systems, attachment systems and mounting brackets for wall panels which provide for four-way movement of the panel or facade.

Description

TECHNICAL FIELD

The present subject matter relates to wall panel systems, attachment apparatuses and mounting brackets for wall panels and related methods. In particular, the present subject matter relates to wall panel systems, attachment systems and mounting brackets for wall panels which provide for four-way movement of the panel or facade.

BACKGROUND

Architectural wall panel systems, including both metal and composite wall panel systems, have been used extensively for some time, primarily in the commercial and industrial building markets. There are a number of factors that may account for the popularity of such wall panel systems. One such factor is the high cost of construction material associated with the construction of commercial and industrial buildings. Another factor is the high durability of these systems. Both the metals and composites used to make the panels for wall panel systems are highly resistant to damage from sun, dirt, moisture, fire, and many other environmental elements. Consequently, the metal and composite wall panel systems have a long life, and may require less maintenance than other alternative building materials and systems.

Architectural wall panel systems can generally be placed into one of two categories: face-sealed architectural panel systems or vented rain-screen architectural panel systems. Face-sealed architectural panel systems include those systems that have a sealant in both the horizontal and vertical joints between adjacent wall panels. The sealants make the wall panel system impermeable to air and water, and may include caulking, gaskets, or other sealants with a similar function. Vented rain-screen architectural panel systems are those systems designed to allow permeability through the joints between adjacent wall panels. The permeable joints allow for breathability and rapid pressure equalization within the wall panel system to prevent pressure buildups behind the wall panels.

Architectural wall panel systems have many advantages, but may also present a number of challenges and disadvantages. One such challenge is the thermal expansion and contraction of the wall panels. The metal and composite materials most commonly used in architectural wall panel systems are subject to natural expansion and contraction due to changes in atmospheric conditions, including heat and humidity. If a means of accommodating this inherent thermal cycling is not provided in the attachment system of the architectural wall panel system then the panels can become warped and cracked, requiring repairing or replacement. Another challenge that may be associated with architectural wall panel systems is directly related to the first issue of thermal cycling, and relates to the effectiveness of sealants used in joints between adjacent wall panels in face-sealed architectural panel systems. Because the joints increase and decrease in size during thermal cycling, sealants often become dislodged and/or cracked and are thereafter ineffective at preventing the infiltration of air and water. As a result, sealants used in face-seated architectural panel systems have proven disappointingly ineffective.

Most existing attachment systems require rigid and precise attachment methods that require extensive on-site preparation or modification. Often, these attachment systems can disengage from the panel and allow the panel to fall out if the panel moves beyond a very limited amount or the attachment system is improperly installed. As such a need exists for an improved attachment system which provides for four-way movement of the panel or facade.

SUMMARY

The present subject matter provides wall panel systems, attachment apparatuses and mounting brackets for wall panels and related methods. In particular, the present subject matter relates to wall panel systems, attachment apparatuses and mounting brackets for wall panels which provide for four-way movement of the panel or facade. Methods related to the assembly of wall panel systems and attachment apparatuses disclosed herein are also provided.

Thus, it is an object of the presently disclosed subject matter to provide wall panel systems, attachment systems and mounting brackets for wall panels and related methods of assembly. While one or more objects of the presently disclosed subject matter having been stated hereinabove, and which is achieved in whole or in part by the presently disclosed subject matter, other objects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present subject matter including the best mode thereof to one of ordinary skill in the art is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

FIG. 1 illustrates a schematic vertical cross-sectional view of an embodiment of a wall panel system that employs an embodiment of an attachment apparatus according to the present subject matter;

FIG. 2A illustrates a top perspective view of an embodiment of an attachment 1t apparatus for a wall panel system according to the present subject matter;

FIG. 2B illustrates a side perspective view of the embodiment of the attachment apparatus according to FIG. 2A for a wall panel system;

FIG. 3A illustrates a side perspective view of an embodiment of a base bracket for use in an attachment apparatus for a wall panel system according to the present subject matter;

FIG. 3B illustrates a top perspective view of the embodiment of the base bracket according FIG. 3A for use in an attachment apparatus for a wall panel system; and

FIG. 4 illustrates side perspective view of an embodiment of a panel bracket for use in an attachment apparatus for a wall panel system according to the present subject matter.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present subject matter.

DETAILED DESCRIPTION

Reference now will be made to the embodiments of the present subject matter, one or more examples of which are set forth below. Each example is provided by way of an explanation of the present subject matter, not as a limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present subject matter without departing from the scope or spirit of the present subject matter. For instance, features illustrated or described as one embodiment can be used on another embodiment to yield still a further embodiment. Thus, it is intended that the present subject matter cover such modifications and variations as come within the scope of the appended claims and their equivalents. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present subject matter, which broader aspects are embodied in exemplary constructions.

Although the terms first, second, right, left, front, back, etc. may be used herein to describe various features, elements, components, regions, layers and/or sections, these features, elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one feature, element, component, region, layer or section from another feature, element, component, region, layer or section. Thus, a first feature, element, component, region, layer or section discussed below could be termed a second feature, element, component, region, layer or section without departing from the teachings of the disclosure herein.

Similarly, when a feature is being described in the present disclosure as “on,” “over,” “above.” or “below” another feature, it is to be understood that the features can either be directly contacting each other or have another feature between the referenced features, unless expressly stated to the contrary. Thus, these terms are simply describing the relative position of the referenced features to each other and do not necessarily mean “on top of” since the relative position above or below depends upon the orientation of the features to the viewer. Additionally, while the terms “height,” “width.” and/or “length” may be used to describe various features herein, these terms are used to distinguish one feature from another and should not be viewed as an absolute term, since the terms can be viewed as dependent upon the orientation and relative position of the referenced features.

Embodiments of the subject matter of the disclosure are described herein with reference to schematic illustrations of embodiments that may be idealized. As such, variations from the shapes and/or positions of features, elements or components within the illustrations as a result of, for example but not limited to, user preferences, manufacturing techniques and/or tolerances are expected. Shapes, sizes and/or positions of features, elements or components illustrated in the figures may also be magnified, minimized, exaggerated, shifted or simplified to facilitate explanation of the subject matter disclosed herein. Thus, the features, elements or components illustrated in the figures are schematic in nature and their shapes and/or positions are not intended to illustrate the precise configuration of the subject matter and are not intended to limit the scope of the subject matter disclosed herein.

The subject matter disclosed herein relates to wall panel systems, attachment systems, and mounting brackets for installing wall panels on a structure. When installed on a structure a plurality of panels, attachment systems, and mounting brackets can be used. FIG. 1 provides an illustrative example of a cross-section of a portion of an embodiment of a wall panel system that can comprise a plurality of wall, or façade, panels secured to a structure with a plurality of attachment apparatuses. In particular, FIG. 1 shows a portion of wall panel system PS that can comprise an attachment apparatus 10 for securing a first panel 20A and a second panel 20B to a structure S. Each panel 20A, 20B can comprise a face-forming portion 22A, 22B that can have a face surface 24A, 24B that, combined with the face surfaces of other panels secured to the structure S form the façcade of the structure S. The face surface 24A, 24B can extend to a perimeter 26A, 26B. Each panel 20A, 20B can also comprise side lip portions 28A, 28B that can extend downward from the perimeter 26A, 26B of the face-forming portion 22A, 22B.

The attachment apparatus 10 can comprise base brackets 12 and panel brackets 50, 70. The panel brackets 50, 70 can be secured to the panels 20A, 20B on lip portions 28A, 28B of the four sides of the panel and the panel brackets 50, 70 can be inserted into the base bracket 12 in different manners as described below. The base bracket 12 can then be secured directly to the structure S or can be secured to the structure S with intervening substrates therebetween. Such substrates can include, but are not limited to, insulating material, barrier material, and/or proofing material to help protect against wind, rain, water, vibration and/or thermal exposure. When installed, the base bracket 12 can extend beneath portions of two wall panels 20A, 20B and are configured to hold two panel brackets 50, 70 as shown in FIGS. 1, 2A, and 2B. By using the base bracket 12, a consistent spacing between the wall panels 20A, 20B can be achieved with some flexibility of movement of the panels 20A, 20B and panel brackets 50, 70 relative to base bracket 12 and to neighboring panels 20A, 20B during installation of the wall panel system PS. Different embodiments of base brackets or end connectors can be used at the perimeters of the structure S being covered. The base brackets 12 and panel brackets 50, 70 can be constructed of extruded metals. For example, processed metals, such as aluminum, titanium, mild steel, or the like, can be extruded through a die mold to form the desired cross-sectional shaped extrusions. These extrusions can then be cut and refined into the desired brackets.

The base bracket 12 can comprise a base body 14 having a first section 16 and a second section 18 as shown in FIGS. 1-3B. The base bracket 12 can also comprise a first retention arm 30 extending from the first section 16 and forming a first cavity 30A having an opening 30B that faces in a first direction A. The base bracket 12 can additionally comprise a second retention arm 32 that can also extend from the first section 16. The second retention arm 32 can form a second cavity 32A having an opening 32B that faces in a second direction B opposite the first direction A so that the first retention arm 30 and the second retention arm 32 form a first holding track 34 with the opening 30B and the opening 32B facing each other. Additionally, the spacing between the first retention arm 30 and the second retention arm 32 can form an opening O (see FIG. 3A) between the first and second retention arms 30, 32 through which a portion of a panel bracket 50, 70 can extend when the respective panel bracket 50, 70 is inserted into the first holding track 34 as shown in FIGS. 1 and 2B. The base bracket 12 can further comprise a third retention arm 36 extending from the second section 18 and forming a cavity 36A having an opening 36B that also faces in the first direction A directed away from the first section 16 to form a second holding track 38 into which a first or second panel bracket 50, 70 can be inserted.

As shown in FIGS. 1, 28, and 38, the base body 14 of the base bracket 12 can have a securement aperture 14A between the first holding track 34 on the first section 16 and the third retention arm 36 on the second section 18. The securement aperture 14A is configured to accommodate a fastener 42 to secure the base body 14 to the structure S as mentioned above.

Referring to FIGS. 1, 2A, and 2B, the attachment apparatus 10 can also comprise the first panel bracket 50 and the second panel bracket 70 for slidable insertion into the base bracket 12. The panel brackets 50, 70 can be interchangeable and have the same cross-sectional shape as shown in FIGS. 1 and 2B. FIG. 4 also illustrates an embodiment of a single panel bracket 50, which will be referenced as well. Each of the first and second panel brackets 50, 70 can comprise a panel engagement head 52, 72 that can be secured to a respective façade panel 20A, 20B to support the panel 20A. 20B above the structure S as described in more detail below.

Each of the first and second panel brackets 50, 70 can also comprise a bracket foot 54, 74 connected to the respective panel engagement head 52, 72. Each bracket foot 54, 74 can have a toe end 56, 76 and a heel end 58, 78. The first and second panel brackets 50, 70 can be interchangeable such that either the first panel bracket 50 or second panel bracket 70 can be inserted into either the first holding track or the second holding track of the base bracket 12. For example, the toe ends 56, 76 of the respective first and second panel brackets 50, 70 can be configured to slideably fit within the first cavity 30A of the first retention arm 30, while the heel ends 58, 78 can be configured to slideably fit within the second cavity 32A of the second retention arm 32 when the respective bracket foot 54, 74 is placed in the first holding track 34 in the first section 16 of the base bracket 12. Additionally, the heel ends 58, 78 of the respective first and second panel brackets 50, 70 are additionally configured to slideably fit within the third cavity 36A of the third retention arm 36 when the respective bracket foot 54, 74 is placed in the second holding track 38 in the second section 18.

In particular, referring to FIG. 3A, the first cavity 30A in the first retention arm 30 can have an interior height H1 that is larger than an interior height H2 within the second cavity 32A in the second retention arm 32. At the same time, the height H2 within the second cavity 32A in the second retention arm 32 can be substantially the same as an interior height H3 within the third cavity 36A in the third retention arm 36, which forms the second holding track 38. In this manner in the embodiment shown, the height H3 within the third cavity 36A is also less than the height H1 within the first cavity 30A. Heights of the toe ends 56, 76 of the respective first and second panel brackets 50, 70 can be sized to snuggly fit within the first cavity 30A in the first retention arm 30, while the heights of the heel ends 58, 78 of the respective first and second panel brackets 50, 70 can be sized to snuggly fit within the second cavity 32A in the second retention arm 32 or the third cavity 36A in the second retention arm 36.

For example, as shown in FIGS. 1 and 4, the toe end 56, 76 of each of the first and second panel brackets 50, 70 can have a height H4 as measured from the exterior surfaces of the toe ends 56, 76 (see FIG. 4) such that each toe end 56, 76 can be securably and slideably inserted within the first cavity 30A in the first retention arm 30 but is not insertable within the second cavity 32A in the second retention arm 32 or the third cavity 36A in the second retention arm 36. The heel end 58, 78 of each of the first and second panel brackets 50, 70, on the other hand, can have a height H5 as measured from the exterior surfaces of the heel ends 58, 78 (see FIG. 4) such that each heel end 58, 78 can be securably and slideably inserted within the second cavity 32A in the second retention arm 32 or the third cavity 36A in the second retention arm 36.

Since the height H1 of the first cavity 30A in the first retention arm 30 is larger than the height H2 within the second cavity 32A in the second retention arm 32, the first holding track 34 does not have equal receiving cavities on either side for accepting the toe end 56, 76 and the heel end 58, 78 of either the first panel bracket 50 or the second panel bracket 70. Rather, the first holding track 34 has receiving cavities of staggered heights so that the first panel bracket 50 or the second panel bracket 70 can only be inserted in a single orientation relative to the first holding track 34. Thereby, if the base bracket 12 is properly installed on the structure S, the panel engagement head 52, 72 of the respective first or second panel bracket 50, 70 can abut the respective panel 20A and hold a portion of the panel 20A in the proper location relative to the other neighboring panels 20B of the façade.

At the same time, since the height H2 within the second cavity 32A in the second retention arm 32 is substantially the same as a height H3 within the third cavity 36A in the third retention arm 36, which forms the second holding track 38, the height H3 within the third cavity 36A is also less than the height H1 within the first cavity 30A. Thereby, the heights H4 of the toe ends 56, 76 of the bracket foot 54, 74 of the respective first and second panel brackets 50, 70 prevents the toe ends 56, 76 from fitting or being inserted into either the second cavity 32A in the second retention arm 32 or the third cavity 36A in the third retention arm 36. Thus, the second holding track 38 has a receiving cavity that permits only the heel ends 58, 78 of the respective first and second panel brackets 50, 70 to be inserted therein. Therefore, the first panel bracket 50 or the second panel bracket 70 can only be inserted in a single orientation in the second holding track 38. In this manner, if the base bracket 12 is properly installed on the structure S, the panel engagement head 52, 72 of the respective first or second panel bracket 50, 70 can abut and hold the respective panel 20B within the façade with proper spacing relative to its neighboring panel 20A, 20B.

Thereby, the first and second panel brackets 50, 70 are interchangeable but ensure the right orientation of the first and second panel brackets 50, 70 relative to the base bracket 14 and to each other, since the second cavity 32A in the second retention arm 32 and the third cavity 36A in the third retention arm 36 permit the heel ends 58, 78 to be securably and slideably inserted therein, while the heights H4 of the respective toe ends 56, 76 prevent insertion of the respective toe ends 56, 76 into either the second cavity 32A in the second retention arm 32 or the third cavity 36A in the third retention arm 36. At the same time, when a bracket foot 54, 74 are properly aligned with the first holding tracks 34, the heights H4 of the toe ends 56, 76 of the respective first or second panel bracket 50, 70 and the heights H5 of the heel ends 58, 78 of the respective first or second panel bracket 50, 70 allow slidable insertion of the respective bracket foots 54, 74 into the cavities 30A, 32A of the respective retention arms 30, 32 of the first holding track 34.

Turning again toward FIG. 3A, the first, second and third retention arms 30, 32, 36 of the base bracket 12 will be described in more detail. The first retention arm 30 can comprise an extension member 80 having a first end 82 and a second end 84 distal from the first end 82. The extension member 80 can be secured to and/or integral with the base body 14 of the base bracket 12 at the first end 82 of the extension member 80. Thereby, the extension member 80 can extend upward from and about perpendicular to the base body 14 of the base bracket 12. The first retention arm 30 can also comprise a cover member 86 that is attached to and/or can be integral with the second end 84 of the extension member 80 distal from the base body 14 of the base bracket 12. The cover member 86 extends outward in the first direction A about parallel to the base body 14 of the base bracket 12, so that the first cavity 30A is formed by the base body 14 as well as the extension member 80 and the cover member 86 of the first retention arm 30. The opening 30B can this extend between the cover member 86 of the first retention arm 30 and the base body 14 of the base bracket 12. Thereby, the extension member 80 and the cover member 86 of the first retention arm 30 can form an inverted “L-shaped” first retention arm.

Similarly, the second retention arm 32 can comprise an extension member 90 having a first end 92 and a second end 94. The extension member 90 of the second retention arm 32 can be secured to and/or integral with the base body 14 of the base bracket 12 at the first end 92 of the respective extension member 90. In this manner, the extension member 90 of the second retention arm 32 can extend upward from and about perpendicular to the base body 14 of the base bracket 12. The second retention arm 32 can also comprise a cover member 96 that is attached to and/or can be integral with the second end 94 of the extension member 90 of the second retention arm 32 distal from the base body 14 of the base bracket 12. The cover member 86 extends outward in the second direction B about parallel to the base body 14 of the base bracket 12. In this manner, the second cavity 32A is formed by the base body 14 as well as the extension member 90 and the cover member 96 of the second retention arm 32 with the opening 32B being formed between the cover member 96 of the second retention arm 32 and the base body 14 of the base bracket 12. Thereby, the opening 32B of the second cavity 32A of the second retention arm 32 faces the opening 32B of the first cavity 30A of the first retention arm 30. With this configuration, the extension member 90 and the cover member 96 of the second retention arm 32 can form an inverted “L-shaped” second retention arm that is flip-flopped, or reversed, so that it is facing the other way as compared to a conventional inverted “L-shape”.

Additionally, the third retention arm 36 can comprise an extension member 100 having a first end 102 and a second end 104. The extension member 100 of the third retention arm 36 can be secured to and/or integral with the base body 14 of the base bracket 12 at the first end 102 of the respective extension member 100. Thereby, the extension member 100 of the third retention arm 36 can extend upward from and about perpendicular to the base body 14 of the base bracket 12. The third retention arm 36 can also comprise a cover member 106 that is attached to and/or can be integral with the second end 104 of the extension member 100 of the third retention arm 36 distal from the base body 14 of the base bracket 12. The cover member 106 extends outward in the first direction A about parallel to the base body 14 of the base bracket 12, so that the third cavity 36A is formed by the base body 14 as well as the extension member 100 and the cover member 106 of the third retention arm 36 with the opening 36B of the third retention arm 36 being formed between the cover member 106 of the third retention arm 36 and the base body 14 of the base bracket 12. Thereby, the extension member 100 and the cover member 106 of the third retention arm 36 can also form an inverted “L-shaped” third retention arm.

In some embodiments, the third retention arm 36 can have an abutment tip 108 as shown in FIGS. 1, 2B, and 3A. The abutment tip 108 can abut a portion of the bracket foot 54, 74 when inserted into the second holding track 38 as shown in FIGS. 1 and 2B. The abutment tip 108 can be angled to abut an upper portion of the bracket foot 54, 74 inward from and above the heal end 58, 78. The abutment tip 108 can offer some additional stability to the respective panel bracket 50, 70 when it is placed in the second holding track 38.

Referring again to FIG. 1 and FIG. 4 (with only a first panel bracket 50 shown therein), the panel brackets 50, 70 will be described in more detail. As shown in FIGS. 1 and 4, the panel engagement head 52, 72 of each of the first and second panel brackets 50, 70 can comprise a support arm 52A, 72A that is capable of supporting the face forming portion of a wall panel 20A. 20B. The panel engagement head 52, 72 of each of the first and second panel brackets 50, 70 can also comprise a securement arm 52B, 72B that extends about perpendicular to the support arm 52A. 72A. The securement arm 52B, 72B can be configured to abut a lip portion 28A, 28B of the wall panel 20A, 20B that can extend about perpendicular to the face-forming portion 22A, 228 of the wall panel 20A, 20B and the securement arm 52B, 72B can be attached to the lip portion 28A, 28B of the respective wall panel 20A, 20B. Additionally, the panel engagement head 52, 72 of each of the first and second panel brackets 50, 70 can comprise a base arm 52C, 72C that can extend about perpendicular to the securement arm 52B, 72B as well as about parallel to the support arm 52A, 72A. The base arm 52C, 72C can be secured to or integral with a portion of the bracket foot 54, 74 of the respective panel bracket 50, 70.

As shown in FIG. 1, the securement arms 52A, 72A of the respective first and second panel brackets 50, 70 can have a panel securement aperture 53, 73 therein. To secure the panels 20A. 20B to the respective first and second panel brackets 50, 70, the panel securement aperture 53, 73 can be aligned with an aperture 25A, 258 in the lip portion 28A, 28B of the façade panel 20A, 20B. Once the panel securement apertures 53, 73 of the respective first and second panel brackets 50, 70 and the lip apertures 25A. 25B of the respective panels 20A. 20B are aligned, fastener devices 27A, 27B can then be inserted to hold the respective first and second panel brackets 50, 70 to the respective panels 20A, 20B. The fastener devices 27A, 27B can comprise, for example, screws, nut and bolt combinations, rivets, snaps, or the like. The support arm 52A and the securement arm 52B can abut the panel on two converging sides to provide additional and enhanced support and stability to the respective panel to which it is attached.

Thus, when a panel bracket is placed in the first holding track 34, such as first panel bracket 50 as shown in FIG. 1, the securement arm 52B of the panel engagement head 52 faces in the first direction A. Alternatively, when a panel bracket is placed in the second holding track 38, such as second panel bracket 70 as shown in FIG. 1, the securement arm 72B of the panel engagement head 72 faces in the second direction B. In this manner, the securement arm 52B of the panel engagement head 52 and the securement arm 72B of the panel engagement head 72 face each other and are aligned to hold neighboring panels 20A, 20B. The interchangeability of the panel brackets 50, 70 can be seen in FIG. 2B with the panel bracket 70 inserted into the first holding track 34 and the panel bracket 50 inserted into the second holding track 38. As stated above, this is because the panel brackets have the same cross-sectional and are just oriented in a different manner to face direction.

Referring to FIGS. 1, 28 and 4, the bracket feet 54, 74 of first and second panel brackets 50, 70 will be described in further detail. The bracket foot 54, 74 of each of the first and second panel brackets 50, 70 further comprises an attachment leg 60A, 60B comprising a first end 62A, 62B and a second end 64A, 64B that is distal from the first end 62A, 62B. The first end 62A, 62B of the attachment leg 60A, 60B can be secured to the panel engagement head 52, 72, such as, for example, the base arm 52C. 72C. The second end 64A. 64B of the attachment leg 60A, 60B can be secured to the toe end 56, 76 and heel end 58, 78 of the bracket foot 54, 74.

A reveal strip support arm 66A, 66B can extend outward from the attachment leg 60A, 60B of the bracket foot 54, 74 and beneath the panel engagement head 52, 72. The reveal strip support arm 66A, 66B and the panel engagement head 52, 72 can form a reveal strip receiving chamber 68A, 68B into which a side of a reveal strip 88 (shown in dotted lines) can be inserted. For example, the reveal strip support arm 66A. 668 can extend outward from the attachment leg 60A, 60B of the bracket foot 54, 74 beneath the base arm 52C, 72C of the panel engagement head 52, 72. The reveal strip support arm 66A, 66B and the base arm 52C, 72C can form the reveal strip receiving chamber 68A, 68B. In some embodiments, as shown in FIG. 4, the attachment leg 60A can provide a different sized and configured reveal strip receiving chamber 68A. 68B. In particular, the attachment leg 60A can extend upward about perpendicular to base portions of the toe end 56 and heel end 58 of the bracket foot 54, 74 (described in more detail below) before extending outward over a portion of the heel end 58 in line with the reveal strip support arm 66A. The attachment leg 60A can then extend up to the base arm 52C of the panel engagement head 52.

As shown in FIGS. 1 and 4, for each of the first and second panel brackets 50, 70, the toe end 56, 76 extends from a first side 63A. 638 of the second end 64A, 64B of the attachment leg 60A, 60B and the heel end 58, 78 extends from an opposing second side 65A, 658 of the second end 64A, 64B of the attachment leg 60A, 60B. The toe end 56, 76 of the bracket foot 54, 74 of each of the first and second panel brackets 50, 70 can comprise a toe base arm 56A, 76A that extends outward from the second end 64A. 64B of the attachment leg 60A. 60B. The toe end 56, 76 can also comprise a toe abutment arm 56B, 76B that can extend upward from an end of the toe base arm 56A, 76A distal to and about parallel to the attachment leg 60A, 60B. Further, the toe end 56, 76 can also comprise a toe support arm 56C, 76C that can extend inward toward the attachment leg 60A, 60B from an end of the toe abutment arm 56B, 76B that is distal from the toe base arm 66A, 76A. Additionally, for each of the first and second panel brackets 50, 70, the heel end 58, 78 can comprise a heel base arm 58A, 78A that extends outward from the second end 64A, 64B of the attachment leg 60A, 60B. The heel end 58, 78 can also comprise a heel abutment arm 58B, 78B that can extend upward from an end of the heel base arm 58A, 78A distal to and about parallel to the attachment leg 60A, 60B. Further, the heel end 58, 78 can comprise a heel support arm 68C, 78C that extends inward toward the attachment leg 60A, 60B from an end of the heel abutment arm 58B. 78B that is distal from the heel base arm 58A, 78A. The heel support arm 58A, 78C also can extend about parallel to the heel base arm 58A, 78A.

Depending on whether the panel system PS is to be sealed or vented, different optional components can also be included for installation between the joints of the panels 20A, 20B. As mentioned above, in some embodiments, a reveal strip 88 (shown in dotted lines) can be placed within the reveal strip receiving chamber 68A, 68B in a vented panel system PS. Alternatively, an insulative material 85 (shown in dotted lines) and a weather strip or sealant 95 (shown in dotted lines) can be placed in the joint in a sealed panel system PS. These components are used to prevent or minimize the amount of water which may be driven between the panel 20 and the structure S. Typically, reveal strip 88 can be used, as a “dry seal” system and material 85 and strip 95 can be used as a “wet seal” system.

Thus, using the attachment apparatus and the brackets described herein, a method of assembling a wall panel system on a structure can be provided. A plurality of wall panels can be provided to create a façade on a structure. Each wall panel can comprise a face-forming portion that can include a face surface that extend to a perimeter and side lip portions extending downward from the perimeter of the face-forming portion. Typically, the panels can be rectangular, for example, a square. A plurality of panel brackets can also be provided. Each panel bracket can comprise a panel engagement head that can be secured to the wall panel to support the panel above the structure. Typically, the panel engagement head of each panel bracket can have a securement arm that can be secured to one of the portions of one of the panels. Each panel bracket can also comprise a bracket foot connected to the panel engagement head with each bracket foot having a toe end and a heel end. As described above a plurality of base brackets are also used. Each base bracket can comprise a base body having a first section and a second section. A first retention arm can extend from the first section and forming a first cavity having an opening that faces in a first direction and a second retention arm can extend from the first section and forming a second cavity having an opening that faces in a second direction opposite the first direction so that the first retention arm and the second retention arm form a first holding track. Each bracket base can also comprise a third retention arm that can extend from the second section and can form a cavity having an opening that faces in the first direction directed away from the first section to form a second holding track. The base body can have a securement aperture between the first holding track on the first section and the third retention arm on the second section. For a rectangular, or square, panel, each panel can have four panel brackets that are attached to the respective four side lip portions of the respective panel.

Initially, end connectors that have receiving cavities like those of the third retention arms on the base brackets on two converging side of the structure being covered, for example, a left side and a bottom side. For each panel in this example, the bracket feet of the panel brackets on the top lip portion and right lip portion of the respective panel are inserted into the first holding track of one or more base brackets, such as two base brackets as shown in FIG. 2A. These bracket feet are inserted into the base brackets such that each toe end of the bracket foot of the panel bracket slideably engages the first retention arm in the first cavity and the heel end of the first panel bracket slideably engages the second retention arm in the second cavity.

The first installed panel can have the bracket foot of the panel bracket on the left side of the panel inserted into the receiving cavity of the left side end connector. Additionally, the bracket foot of the panel bracket on the bottom side of the first installed panel can be inserted into the receiving cavity of the bottom side end connector. Once the panel is properly positioned on the structure, the base brackets on the top and left panel brackets can be secured to the structure as described above.

The second installed panel can have the bracket foot of the panel bracket on the bottom side of the second installed panel inserted into the receiving cavity of the bottom side end connector, while the bracket foot of the panel bracket on the bottom side of the first installed panel can be inserted into the second holding tracks on the base brackets secured to the structure and that are extending outward from the left side of the first installed panel. Panels can be installed in a similar fashion until a first row of panels is installed. Then a second row of panels can be installed in a similar fashion, but instead of inserting the receiving cavity of the bottom end connector as described above, the bracket feet of the panel brackets on the bottom side of the panels can engage the third retention arms of the base brackets secured to the below neighboring panels and the structure. Installation in this manner can continue until the wall panel system covers the appropriate and desired area of the structure being covered.

Thus, for example, a method of assembling a wall panel system on a structure can be provided. The method can comprise providing a plurality of wall panels with each wall panel comprising a face-forming portion that comprises a face surface that extends to a perimeter and side lip portions extending downward from the perimeter of the face-forming portion. A plurality of base brackets can also be provided. Each base bracket can comprise a base body having a first section and a second section. Each base bracket can also comprise a first retention arm extending from the first section and forming a first cavity having an opening in a first direction and a second retention arm extending from the first section and forming a second cavity having an opening in a second direction opposite the first direction so that the first retention arm and the second retention arm form a first holding track. Each base bracket can further comprise a third retention arm extending from the second section and forming a cavity having an opening in the first direction directed away from the first section to form a second holding track with the base body having a securement aperture between the first holding track on the first section and the third retention arm on the second section. A plurality of panel brackets can also be provided for slidable insertion into the base bracket. Each panel bracket can comprise a panel engagement head that can be secured to one of the lip portions of the wall panel to support the panel above the structure and a bracket foot connected to the panel engagement head with the bracket foot having a toe end and a heel end.

To further explain the method of assembling the wall panels, reference will be made to first and second wall panels, a base bracket, and first and second panel brackets. The method can further comprise securing a side lip portion of a first panel to a panel engagement head of a first panel bracket and securing a side lip portion of a second panel to a panel engagement head of a second panel bracket. The bracket foot of the first panel bracket can be inserted into the first holding track of the base bracket such that the toe end of the bracket foot of the first panel bracket slideably engages the first retention arm in the first cavity and the heel end of the first panel bracket slideably engages the second retention arm in the second cavity. The base bracket can be secured to the structure by inserting a fastener device through the securement aperture and into the structure. The bracket foot of the second panel bracket can then be inserted into the second holding track of the installed base bracket such that the heel end of the bracket foot of the second panel bracket slideably engages the third retention arm in the third cavity. The first and second panels can then be aligned as needed. Further, other wall panels can be secured to the structure in similar fashion using the other base brackets and panel brackets so that the portion of the structure intended to be covered is covered by the wall panel system.

These and other modifications and variations to the present subject matter may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present subject matter, which is more particularly set forth herein above. In addition, it should be understood the aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the present subject matter.

Claims

1. An attachment apparatus for securing a first panel and a second panel to a structure, the attachment apparatus comprising:

a base bracket, comprising: a base body having a first section and a second section, the base body securable to the structure; a first retention arm extending from the first section and forming a first cavity having an opening in a first direction; a second retention arm extending from the first section and forming a second cavity having an opening in a second direction opposite the first direction so that the first retention arm and the second retention arm form a first holding track; and a third retention arm extending from the second section and forming a cavity having an opening in the first direction directed away from the first section to form a second holding track; and

a first panel bracket and a second panel bracket for slidable insertion into the base body, each of the first and second panel brackets comprising: a panel engagement head securable to a wall panel to support the panel above the structure; and a bracket foot connected to the panel engagement head, the bracket foot having a toe end and a heel end, the toe end configured to slideably fit within the first cavity of the first retention arm and the heel end configured to slideably fit within the second cavity of the second retention arm when the bracket foot is placed in the first holding track in the first section and the heel end configured to slideably fit within the third cavity of the third retention arm when the bracket foot is placed in the third retention arm in the second section.

2. The apparatus according to claim 1, wherein a height within the first cavity in the first retention arm is larger than a height within the second cavity in the second retention arm and the height within the second cavity in the second retention arm is substantially the same as a height within the third cavity in the third retention arm.

3. The apparatus according to claim 2, wherein the toe end of each of the first and second panel brackets has a height such that each toe end is securably and slideably insertable within the first cavity in the first retention arm but is not insertable within the second cavity in the second retention arm or the third cavity in the second retention arm.

4. The apparatus according to claim 3, wherein the heel end of each of the first and second panel brackets has a height such that each of the heel ends is securably and slideably insertable within the second cavity in the second retention arm with the respective toe end inserted within the first cavity in the first retention arm when the respective panel bracket is inserted into the first holding track and each of the heel ends is securably and slideably insertable within the third cavity in the third retention arm when the respective panel bracket is inserted into the second holding track.

5. The apparatus according to claim 1, wherein the first retention arm of the base bracket comprises:

an extension member having a first end and a second end, the extension member secured to the base body at the first end and extending upward from and about perpendicular to the base body;

a cover member attached to the second end of the extension member distal from the base body and extending outward in the first direction about parallel to the base body so that the first cavity is formed by the base body and the extension member and the cover member of the first retention arm with the opening formed between the cover member of the first retention arm and the base body.

6. (canceled)

7. The apparatus according to claim 1, wherein the second retention arm of the base bracket comprises:

an extension member having a first end and a second end, the extension member secured to the base body at the first end and extending upward from and about perpendicular to the base body;

a cover member attached to the second end of the extension member of the second retention arm distal from the base body and extending outward in the second direction about parallel to the base body so that the second cavity is formed by the base body and the extension member and the cover member of the second retention arm with the opening formed between the cover member of the second retention arm and the base body and facing the first cavity of the first retention arm.

8. (canceled)

9. The apparatus according to claim 1, wherein the third retention arm of the base bracket comprises:

an extension member having a first end and a second end, the extension member secured to the base body at the first end and extending upward from and about perpendicular to the base body;

a cover member attached to the second end of the extension member of the third retention arm distal from the base body and extending outward in the first direction about parallel to the base body so that the third cavity is formed by the base body and the extension member and the cover member of the third retention arm with the opening formed between the cover member of the third retention arm and the base body.

10. (canceled)

11. The apparatus according to claim 1, wherein first retention arm and second retention arm form an opening therebetween through which a portion of the first panel bracket extends when the first panel bracket is inserted into the first holding track.

12. The apparatus according to claim 1, wherein the panel engagement head of each of the first and second panel brackets comprises:

a support arm that is capable of supporting a face forming portion of a wall panel;

a securement arm that extends about perpendicular to the support arm, the securement arm configured to abut a lip portion of the wall panel that extends about perpendicular to the face-forming portion of the wall panel and the securement arm capable of attaching to the lip portion of the wall panel; and

a base arm that extends about perpendicular to the securement arm and extends about parallel to the support arm, the base arm being secured to the bracket foot of the respective panel bracket.

13. The apparatus according to claim 12, wherein the securement arm comprises a panel securement aperture that is alignable with an aperture in the lip portion of the wall panel and into which a fastener device is insertable upon alignment.

14. The apparatus according to claim 12, wherein the securement arm of the panel engagement head faces the first direction when the respective panel bracket resides in the first holding track and the securement arm of the panel engagement head faces the second direction when the respective panel bracket resides in the second holding track.

15. The apparatus according to claim 12, wherein the bracket foot of each of the first and second panel brackets further comprises an attachment leg comprising a first end that is secured to the base arm of the panel engagement head and a second end that is distal from the first end and is secured to the toe end and heel end of the bracket foot.

16. The apparatus according to claim 15, further comprising a reveal strip support arm that extends outward from the attachment leg of the bracket foot and beneath the base arm of the panel engagement head, the reveal strip support arm and the base arm forming a reveal strip receiving chamber into which a side of a reveal strip is insertable.

17.-22. (canceled)

23. A wall panel system for securing wall panels to a structure, the wall panel system comprising:

a plurality of wall panels, each wall panel comprising a face-forming portion that comprises a face surface that extend to a perimeter and side lip portions extending downward from the perimeter of the face-forming portion;

a plurality of base brackets, each base bracket securable to the structure between two wall panels, comprising: a base body having a first section and a second section, a first retention arm extending from the first section and forming a first cavity having an opening in a first direction, a second retention arm extending from the first section and forming a second cavity having an opening in a second direction opposite the first direction so that the first retention arm and the second retention arm form a first holding track; a third retention arm extending from the second section and forming a cavity having an opening in the first direction directed away from the first section to form a second holding track, and the base body having a securement aperture between the first holding track on the first section and the third retention arm on the second section, the securement aperture configured to accommodate a fastener to secure the base body to the structure; and

a panel bracket for each side lip portion of each wall panel with each panel bracket securable to the corresponding side lip portion of a respective wall panel, each panel bracket comprising: a panel engagement head that abuts and is securable to the corresponding side lip portion of the respective wall panel to support the panel above the structure; and a bracket foot connected to the panel engagement head, the bracket foot comprising an attachment leg, a toe end, and a heel end, the toe end configured to slideably fit within the first cavity of the first retention arm of a corresponding base bracket and the heel end configured to slideably fit within the second cavity of the second retention arm when the bracket foot is placed in the first holding track in the first section of the corresponding base bracket and the heel end configured to slideably fit within the third cavity of the third retention arm when the bracket foot is placed in the third retention arm in the second section of a corresponding base bracket.

24. A panel bracket for securing to a lip portion of a wall panel to support the wall panel proximate to a structure, the panel bracket comprising:

a panel engagement head that abuts and is securable to a lip portion of a wall panel to support the panel above a structure; and

a bracket foot comprising: an attachment leg having a first end and a second end, the attachment leg connected to the panel engagement head at the first end of the attachment leg; a toe end extending from a first side of the second end of the attachment leg; a heel end extending from an opposing second side of the second end of the attachment leg; and the toe end having a greater height than a height of the heel end.

25. The panel bracket according to claim 24, wherein the panel engagement head of the panel bracket comprises:

a support arm that is capable of supporting a face forming portion of the wall panel;

a securement arm that extends about perpendicular to the support arm, the securement arm configured to abut the lip portion of the wall panel that extends about perpendicular to the face-forming portion of the wall panel and the securement arm capable of attaching to the lip portion of the wall panel; and

a base arm that extends about perpendicular to the securement arm and extends about parallel to the support arm, the base arm being secured to the attachment leg of bracket foot.

26. The panel bracket according to claim 25, wherein the securement arm comprises a panel securement aperture that is alignable with an aperture in the lip portion of the wall panel and into which a fastener device is insertable upon alignment.

27. (canceled)

28. The panel bracket according to claim 24, further comprising a reveal strip support arm that extends outward from the attachment leg of the bracket foot and beneath the panel engagement head, the reveal strip support arm and the panel engagement head forming a reveal strip receiving chamber into which a side of a reveal strip is insertable.

29. The panel bracket according to claim 24, wherein the toe end of the bracket foot comprises:

a toe base arm that extends outward from the second end of the attachment leg;

a toe abutment arm that extends upward from an end of the toe base arm distal from and about parallel to the attachment leg; and

a toe support arm that extends inward toward the attachment leg from an end of the toe abutment arm that is distal from the toe base arm.

30. The panel bracket according to claim 24, wherein the heel end of the bracket foot comprises:

a heel base arm that extends outward from the second end of the attachment leg;

a heel abutment arm that extends upward from an end of the heel base arm distal from and about parallel to the attachment leg; and

a heel support arm that extends inward toward the attachment leg from an end of the heel abutment arm that is distal from the heel base arm, the heel support arm extending about parallel to the heel base arm.

31. (canceled)