PERIMETER EXTRUSIONS AND KITS FOR BUILDING PANEL MOUNTING SYSTEMS, AND METHODS OF MAKING A PANEL ASSEMBLY

Abstract

A perimeter extrusion for mounting a panel to a building wall is disclosed. The perimeter extrusion includes a panel engaging portion, and an anchor engaging portion. The panel engaging portion has a fastener slot sized to receive a fastener, which includes a slot upper wall opposite and spaced apart from a slot lower wall by a slot inner wall connecting the slot upper and lower walls at the slot inner end, and a slot outer end defining a slot opening. Each slot upper and lower wall has an interior face extending between the slot inner and outer ends, and at least a portion of at least one of the interior faces is serrated for engaging a fastener. The anchor engaging portion is connected to the panel engaging portion and has an anchor slot sized to receive an anchor flange of an anchor extrusion.

Description

FIELD

This disclosure relates to the field of panel systems for covering building walls, and in particular, to perimeter extrusions and kits for mounting panels to building walls, and methods of making a panel assembly.

INTRODUCTION

Architectural panels are sometimes applied to the facing of commercial and industrial building walls as an alternative to more expensive traditional brick and stone facades. Such panels may be mounted to the building walls using anchor extrusions and perimeter extrusions.

SUMMARY

In a first aspect, a perimeter extrusion for mounting a panel to a building wall is disclosed. The panel has a panel front wall, and at least one panel sidewall extending along a periphery of the panel front wall. The perimeter extrusion may comprise a panel engaging portion and an anchor engaging portion. The panel engaging portion may have a fastener slot sized to receive a fastener. The fastener slot may include a slot upper wall opposite and spaced apart from a slot lower wall by a slot inner wall connecting the slot upper and lower walls at the slot inner end, and a slot outer end defining a slot opening. Each slot upper and lower wall may have an interior face extending between the slot inner and outer ends, and at least a portion of at least one of the interior faces may be serrated for engaging a fastener. An anchor engaging portion may be connected to the panel engaging portion having an anchor slot sized to receive an anchor flange of an anchor extrusion.

In some embodiments, at least a portion of the interior face of both the slot upper and lower walls may be serrated.

In some embodiments, the entire interior face of the at least one of the interior faces may be serrated.

In some embodiments, the anchor slot may comprise a slot upper wall opposite and spaced apart from a slot lower wall by a slot inner wall connecting the slot upper and lower walls at the slot inner end, and a slot outer end defining a slot opening.

In some embodiments, the slot inner ends of the fastener and anchor slots may be both positioned at an inner end of the perimeter extrusion.

In some embodiments, the perimeter extrusion may further comprise a filler strip engaging portion having a filler strip slot sized to receive a filler strip for covering an anchor extrusion.

In some embodiments, the filler strip slot may comprise a slot upper wall opposite and spaced apart from a slot lower wall by a slot inner wall connecting the slot upper and lower walls at the slot inner end, and a slot outer end defining a slot opening.

In some embodiments, the slot inner wall of the anchor slot may meet the slot inner wall of the filler strip slot at a slot interface; and a common slot dividing wall extending from the slot interface outwardly may form the slot upper wall of the anchor slot and the slot lower wall of the filler strip slot.

In some embodiments, the panel engaging portion may be positioned above the anchor engaging portion.

In some embodiments, the slot upper wall of the anchor slot may be positioned below and spaced apart from the slot lower wall of the fastener slot.

In some embodiments, the perimeter extrusion may be an integrally formed extruded article.

In another aspect, a kit for mounting a panel to a building wall is provided. The panel may have a panel front wall, and at least one panel sidewall extending along a periphery of the panel front wall. The kit may comprise at least one perimeter extrusion, and at least one rivet. The at least one perimeter extrusion may comprise a panel engaging portion and an anchor engaging portion. The panel engaging portion may have a fastener slot. The fastener slot may include a slot upper wall opposite and spaced apart from a slot lower wall by a slot inner wall connecting the slot upper and lower walls at the slot inner end, and a slot outer end defining a slot opening. Each slot upper and lower wall may have an interior face extending between the slot inner and outer ends, and at least a portion of at least one of the interior faces may be serrated. An anchor engaging portion may be connected to the panel engaging portion having an anchor slot shaped to receive an anchor flange of an anchor extrusion. The at least one rivet may have a rivet head and a rivet body. The rivet body may have (i) an unexpanded size for insertion through a panel sidewall and the slot opening into the fastener slot of the perimeter extrusion, and (ii) an expanded size for engaging the serrated portion of the at least one interior face to prevent withdrawal of the rivet from the fastener slot.

In some embodiments, the rivet body may be made of malleable metal to be indented by teeth of the serrated portion when expanded.

In some embodiments, the rivet may be a blind rivet.

In some embodiments, the rivet head may be larger than a height of the slot opening.

In some embodiments, the rivet body may form two bulges for twice engaging the serrated portion.

In another aspect, a method of making a panel assembly for securing to a building wall is provided. The method may comprise placing a perimeter extrusion against an inside face of a panel sidewall of a panel, the panel including a panel front wall, the panel sidewall extending along a perimeter of the panel front wall, and the panel sidewall including at least one fastener opening, the perimeter extrusion including (i) a panel engaging portion having a serrated fastener slot having a slot opening facing the panel sidewall, and (ii) an anchor engaging portion; and inserting a rivet body of a rivet into the serrated fastener slot through the fastener opening, and expanding the rivet body into engagement with the serrated fastener slot to permanently fasten the perimeter extrusion to the panel sidewall.

In some embodiments, expanding the rivet body may comprise interlocking the rivet body with teeth of the serrated fastener slot.

In some embodiments, expanding the rivet body may comprise teeth of the serrated fastener slot forming mating indentations in the rivet body.

In some embodiments, the rivet may be a blind rivet including a mandrel, and expanding the rivet body may comprise drawing the mandrel into the rivet body.

In some embodiments, expanding the rivet body comprises forming two bulges in the rivet body, each bulge engaging the serrated fastener slot.

DRAWINGS

FIG. 1 is a perspective view of panel assemblies connected to anchor extrusions;

FIG. 2 is a perspective view of a kit for mounting a panel to a building wall;

FIG. 3A is a side elevation view of a perimeter extrusion placed against a panel;

FIG. 3B is a side elevation view of the perimeter extrusion of FIG. 3A with an unexpanded rivet inserted through the panel into the perimeter extrusion;

FIG. 3C is a side elevation view of the perimeter extrusion of FIG. 3B with the rivet expanded inside the perimeter extrusion; and

FIG. 4 is a side elevation view of the expanded rivet of FIG. 3C.

DESCRIPTION OF VARIOUS EMBODIMENTS

Numerous embodiments are described in this application, and are presented for illustrative purposes only. The described embodiments are not intended to be limiting in any sense. The invention is widely applicable to numerous embodiments, as is readily apparent from the disclosure herein. Those skilled in the art will recognize that the present invention may be practiced with modification and alteration without departing from the teachings disclosed herein. Although particular features of the present invention may be described with reference to one or more particular embodiments or figures, it should be understood that such features are not limited to usage in the one or more particular embodiments or figures with reference to which they are described.

The terms “an embodiment,” “embodiment,” “embodiments,” “the embodiment,” “the embodiments,” “one or more embodiments,” “some embodiments,” and “one embodiment” mean “one or more (but not all) embodiments of the present invention(s),” unless expressly specified otherwise.

The terms “including,” “comprising” and variations thereof mean “including but not limited to,” unless expressly specified otherwise. A listing of items does not imply that any or all of the items are mutually exclusive, unless expressly specified otherwise. The terms “a,” “an” and “the” mean “one or more,” unless expressly specified otherwise.

As used herein and in the claims, two or more parts are said to be “coupled”, “connected”, “attached”, or “fastened” where the parts are joined or operate together either directly or indirectly (i.e., through one or more intermediate parts), so long as a link occurs. As used herein and in the claims, two or more parts are said to be “directly coupled”, “directly connected”, “directly attached”, or “directly fastened” where the parts are connected directly in physical contact with each other. As used herein, two or more parts are said to be “rigidly coupled”, “rigidly connected”, “rigidly attached”, or “rigidly fastened” where the parts are coupled so as to move as one while maintaining a constant orientation relative to each other. None of the terms “coupled”, “connected”, “attached”, and “fastened” distinguish the manner in which two or more parts are joined together.

Further, although process steps, method steps, or the like may be described (in the disclosure and/or in the claims) in a sequential order, such processes and methods may be configured to work in alternate orders. In other words, any sequence or order of steps that may be described does not necessarily indicate a requirement that the steps be performed in that order. The steps of processes and methods described herein may be performed in any order that is practical. Further, some steps may be performed simultaneously.

Referring to FIG. 1, two panel assemblies 100 are shown mounted to anchor extrusions 104 in accordance with at least one embodiment. As shown, panel assembly 100 may include a panel 108 and at least one perimeter extrusion 112 fastened to the panel 108. Panel assembly 100 may be connected to one or more anchor extrusions 104 for mounting the panel 108 to a building wall.

In some prior panel assemblies, a perimeter extrusion is fastened to a panel sidewall by placing the perimeter extrusion against the panel sidewall, and drilling a plurality of holes into the perimeter extrusion through the panel sidewall, inserting a rivet into each hole, and then expanding each rivet to permanently fasten the perimeter extrusion to the panel. However, the drilling step can add considerable labor costs to the panel assemblies, and create waste drillings which can ruin panels with scratches as they are handled on a work surface. In one aspect, perimeter extrusion 112 may be free of drilled holes, which may reduce labor costs and waste panels in the manufacturing of panel assemblies 100.

Each panel 108 may include a panel front wall 116 and one or more panel sidewalls 120 extending along a periphery of the panel front wall 116. In the illustrated example, panel front wall 116 is rectangular having four side edges 124, and two panel sidewalls 120 extend along two of the side edges 124 opposite one another. In alternative embodiments, panel front wall 116 may take any suitable shape. For example, panel front wall 116 may have a regular shape (triangular, pentagonal, etc.) or an irregular shape (e.g. a multi-sided polygon). Further, panel 108 may include any number of panel sidewalls 120. Panel sidewalls 120 may extend about a fractional portion of the periphery of panel front wall 116, or about substantially the entire periphery of panel front wall 116. For example, panel front wall 116 may include additional panel sidewalls 120 extending along the remaining two side edges 124 shown without panel sidewalls 120.

In the illustrated embodiment, panel front wall 116 is integrally formed with panel sidewalls 120. For example, panel front wall 116 and sidewalls 120 may be formed as a continuous sheet of material with peripheral regions that have been bent to form panel sidewalls 120. In other examples, panel 108 including panel front wall 116 and panel sidewalls 120 may be integrally formed by casting or extrusion. In alternative embodiments, one or more of panel sidewalls 120 may be separately formed and connected to panel front wall 116. For example, one or more of panel sidewalls 120 may be connected to panel front wall 116 by adhesive, fasteners (e.g. rivets, screws, bolts, or nails), or by welding.

Panel front wall 116 and sidewalls 120 may be formed of any suitable material(s), such as metal, plastic, stone, or glass. Panel front wall 116 may be formed of the same or different material than panel sidewalls 120. Panel sidewalls 120 may be all formed of the same material, or one or more of panel sidewalls 120 may be formed of different material(s) than other panel sidewall(s) 120.

In some embodiments, panel 108 may formed of multiple layers of material. For example, one or more of panel front wall 116 and panel sidewalls 120 may be formed of multiple layers of material. As shown, each of panel front wall 116 and panel sidewalls 120 may include an outside face 128, which may be visible when panel 108 is mounted to a building wall, and an inside face 132. One or more of panel front wall 116 and panel sidewalls 120 may include an outside layer 136 which forms the outside face 128, and an inside layer 140 which forms the inside face 132. In the illustrated example, each of panel front wall 116 and panel sidewalls 120 is a trilaminate including an outside layer 136, an inside layer 140, and a core 144 between the inside and outside layers 136 and 140. The layers 136 and 140, and the core 144 may be the same or different materials. For example, the outside and inside layers 136 and 140 may be a metal such as aluminum or another material, and the core 144 may be a plastic material such as polyethylene or another material. Alternatively, all three layers 136, 140, and 144 may be the same material, whether a metal, plastic, or another material (e.g. glass or stone).

One or both of the outside and inside faces 128 and 132 may be coated by paint, a laminate, an anodized layer, or another type of coating. For example, a coating imparting particular color(s) and/or texture(s) may be applied to the outside face(s) 128 of panel front wall 116 and/or sidewalls 120. Alternatively, one or both of outside and inside faces 128 and 132 may be uncoated bare material.

As shown, panel front wall 116 may be substantially planar, and panel sidewalls 120 may extend rearwardly substantially perpendicular to panel front wall 116. In alternative embodiments, panel front wall 116 may have a non-planar surface profile. In some embodiments, panel sidewalls 120 may extend rearwardly of panel wall 116 at a non-perpendicular angle (e.g. at 60 to 120 degrees to panel front wall 116).

Mounting a panel 108 to a building wall may include fastening anchor extrusions 104 to the building wall (e.g. with concrete screws or by another suitable method), fastening perimeter extrusions 112 to panel 108, and then mounting perimeter extrusions 112 onto anchor extrusions 104. Perimeter extrusions 112 may be fastened to panel 108 by fasteners. In the illustrated example, perimeter extrusions 112 are fastened to panel 108 by rivets 148. In alterantive embodiments, perimeter extrusions 112 may be fastened to panel 108 by screws (not shown). In some embodiments, perimeter extrusions 112 may be free of drilled openings which may reduce or eliminate drilling labor costs and ruined panels from scratches by waste drillings.

Reference is now made to FIGS. 1 and 2. FIG. 2 shows a kit 152 for mounting a panel 108 to a building wall. Kit 152 includes at least one perimeter extrusion 112 and at least one fastener. The fastener(s) may include rivets 148 and/or screws (not shown). As exemplified, perimeter extrusion 112 may include a panel engaging portion 156 for engaging panel 108, and an anchor engaging portion 160 for engaging anchor extrusion 104. Panel engaging portion 156 includes a fastener slot 164 for receiving a fastener which joins perimeter extrusion 112 to panel 108. As shown in FIGS. 3A-3C, perimeter extrusion 112 may be placed against inside face 132 of panel sidewall 120 (see FIG. 3A), and rivets 148 may be inserted through fastener openings 264 (FIG. 1) in panel sidewall 120 into fastener slot 164 of a panel engaging portion 156 of perimeter extrusion 112 (see FIG. 3B), and then expanded to permanently join perimeter extrusion 112 to panel sidewall 120 (see FIG. 3C). As exemplified, no holes may need to be drilled into perimeter extrusion 112 to fasten perimeter extrusion 112 to panel sidewall 120 with rivets 148.

Referring again to FIG. 1, panel assembly 100, including panels 108 and perimeter extrusions 112, may be mounted to any suitable anchor extrusions 104. Anchor extrusion 104 may include an anchor base 168 for connecting to a building wall, and one or more anchor arms 172 extending from anchor base 168. Anchor engaging portion 160 may include one or more anchor slots 176 for receiving anchor arms 172 to connect perimeter extrusion 112 to anchor extrusion 104.

Referring now to FIGS. 1 and 2, in some cases, it may be desirable to protect and/or reduce the visibility of anchor extrusions 104 between adjacent panels 108. As shown, perimeter extrusions 112 may include a filler strip engaging portion 180 for holding a filler strip 184 (FIG. 1) over top of anchor extrusion 104. Filler strip engaging portion 180 may include a filler strip slot 188 shaped to receive an end of filler strip 184. As shown, adjacent anchor extrusions 104 of adjacent panel assemblies 100 may receive opposite ends of a filler strip 184 in their respective filler strip slot 188 for holding the filler strip 184 over the anchor extrusion 104, which may protect and/or conceal the visibility of the anchor extrusion 104.

Referring to FIG. 2, slots 164, 176, and 188 of perimeter extrusion 112 may take any suitable form. As exemplified, slot 164 may include a slot upper wall 192 opposite and spaced apart from a slot lower wall 196. Slot upper and lower walls 192 and 196 may extend between the slot outer end 204 and the slot inner end 208. A slot inner wall 212 may connect the slot upper and lower walls 192 and 196 at the slot inner end 208. Slot inner wall 212 may extend transversely to the upper and lower walls 192 and 196 (e.g. perpendicularly thereto). The slot outer end 204 may define a slot opening 216. Similarly, slot 164 may include a slot upper wall 192′, slot lower wall 196′, slot outer end 204′, slot inner end 208′, slot inner wall 212′, and slot opening 216′. Further, slot 188 may include a slot upper wall 192″, slot lower wall 196″, slot outer end 204″, slot inner end 208″, slot inner wall 212″, and slot opening 216″.

Still referring to FIG. 2, slots 164, 176, and 188 may have a respective depth 220, 220′, and 220″ measured from their respective slot outer end 204 to slot inner end 208, a respective width 224 measured in the direction 228 of extrusion, which may be perpendicular to their respective depth 220, and a respective height 226, 226′, and 226″ measured as the distance between their slot upper wall 192 and slot lower wall 196, which may be perpendicular to their width 224. As shown, each width 224 may be equal to width 232 of extrusion 228. For each slot 164, 176, and 188, their respective upper and lower walls 192 and 196 may be parallel to provide a constant slot height 226, or non-parallel which may provide a slot height 226 that varies between their slot outer and inner ends 204 and 208.

Each of slots 164, 176, and 188 may face any suitable direction. In the illustrated embodiment, slots 164, 176, and 188 each face outwardly. As shown, slot outer end 204 of each slot may be positioned at or proximate an outer end 236 of perimeter extrusion 112, and slot inner end 208 of each slot may be positioned at or proximate an inner end 240 of perimeter extrusion 112. In alternative embodiments, one or more of slots 164, 176, and 188 may face in a different direction (e.g. inwardly).

Referring to FIG. 3A, perimeter extrusion 112 may have an upper end 244 positioned closest to panel front wall 116 when installed, and an opposite lower end 248 positioned remotely from panel front wall 116 when installed. Panel engaging portion 156 may be positioned above anchor engaging portion 160 (i.e. panel engaging portion 156 may be positioned closer to upper end 244 than anchor engaging portion 160). Where perimeter extrusion 112 includes a filler strip engaging portion 180, filler strip engaging portion 180 may be positioned between panel engaging portion 156 and anchor engaging portion 160.

Referring to FIGS. 1 and 2, slot 164, 176, and 188 may be formed by discrete walls, or two or more of slots 164, 176, and 188 may share a wall in common. In the illustrated embodiment, fastener slot 164 has walls 192, 196, and 212 which are discrete from the walls of anchor and filler strip slots 176 and 188. As shown, slot lower wall 196 of fastener slot 164 may be spaced apart from slot upper wall 192 of filler strip slot 188. This may permit filler strip slot 188 and anchor slot 176 to be positioned below panel sidewalls 120 for connecting with filler strips 184 (FIG. 1) and anchor extrusions 104 (FIG. 1), respectively. This may also provide perimeter extrusion with a second anchor slot 250 for receiving an anchor arm 172. As shown, second anchor slot 250 may be formed by a slot outer wall 251 connecting the slot lower wall 196 of fastener slot 164 and the slot upper wall of filler strip slot 188. Second anchor slot 250 may face inwardly with slot inner end 208″′ defining a slot opening 216″′.

Referring to FIG. 2, in alternative embodiments, a common wall may form slot lower wall 196 of fastener slot 164 and slot upper wall 192 of filler strip slot 188 (or of anchor slot 176 if perimeter extrusion 112 is absent a filler strip engaging portion 180). As shown, a common slot dividing wall 252 may form the slot lower wall 196 of filler strip slot 188 and the slot upper wall 192 of anchor slot 176. Common slot dividing wall 252 may extend from an interface 254 where the slot inner walls 212 of anchor slot 176 and filler strip slot 188 meet. In alternative embodiments, slot lower wall 196 of filler strip slot 188 may be spaced apart from slot upper wall 192 of anchor slot 176.

Referring to FIG. 3A, in some embodiments, perimeter extrusion 112 may include an extrusion upper wall 256 spaced apart and connected to slot upper wall 192 of fastener slot 164. Extrusion upper wall 256 may space fastener slot 164 from extrusion upper end 244. This may permit fastener slot 164 to be more centrally aligned with the height 260 of panel sidewall 120 when extrusion upper end 244 is placed in contact with inside face 132 of panel front wall 116. In alternative embodiments, slot upper wall 192 of fastener slot 164 may form extrusion upper end 244, and perimeter extrusion 112 may not include a discrete extrusion upper wall 256.

Reference is now made to FIGS. 3A-3C, which show a method of making a panel assembly 100 for securing to a building wall, in accordance with at least one embodiment. As shown in FIG. 3A, an anchor extrusion 104 may be placed against an inside face 132 of panel sidewall 120. For example, outer end 236 of perimeter extrusion 112 may be placed in contact with inside face 132 of panel sidewall 120. Upper end 244 of perimeter extrusion 112 may face inside face 132 of panel front wall 116 and lower end 248 of perimeter extrusion 112 may face away from panel front wall 116. In some embodiments, upper end 244 of perimeter extrusion 112 may also be placed in contact with inside face 132 of panel front wall 116. In alternative embodiments, upper end 244 of perimeter extrusion 112 may be spaced apart from inside face 132 of panel front wall 116.

Referring to FIG. 1, in some embodiments, panel 108 may include fastener openings 264 formed in panel sidewalls 120 to provide passage for a fastener such as rivets 148, or screws. Openings 264 may be formed at the time of manufacturing panel 108 prior to assembling panel assemblies 100 (e.g. by drilling, stamping, or molding). This may permit assembly of panel assemblies 100 from perimeter extrusions 112, prepared panels 108, and fasteners without drilling. In turn, this may mitigate the risk of scrap drillings scratching the outside face 128 of panel 108 during assembly.

Referring again to FIG. 3A, perimeter extrusion 112 may be placed against inside face 32 of panel sidewall 120 with fastener slot 164 aligned with the pre-formed (e.g. drilled or punched) fastener openings 264 (FIG. 1). As shown, a center of fastener slot 164 may be spaced below upper end 244 of perimeter extrusion 112 by a predetermined distance, such that when upper end 244 of perimeter extrusion 112 is placed against inside face 132 of panel front wall 116, fastener slot 164 is aligned with fastener openings 264. In alternative embodiments, fastener openings 264 may be drilled at the time of assembling panel assembly 100 to adapt to the particular dimensions of perimeter extrusions 112.

As shown in FIG. 3B, a rivet 148 may be inserted through fastener opening 264 (FIG. 1) in panel sidewall 120 into fastener slot 164 of perimeter extrusion 112. Rivet 148 may be any suitable rivet. In the illustrated example, rivet 148 is a blind rivet having a rivet body 268 extending from a rivet head 272, and a rivet mandrel 276 extending coaxially through the rivet body 268 and rivet head 272. In use, rivet mandrel 276 may be drawn through rivet body 268 in the direction 280 while holding rivet body 268 and rivet head 272 in place to expand the rivet body 268 into engagement with the fastener slot 164. After expansion, rivet mandrel 276 may break apart.

Rivet 148 may have any suitable rivet head 272. In the illustrated embodiment, rivet 148 has a flat countersunk rivet head 272, which seats in the countersink of fastener opening 264. This may permit rivet 148 to be flush or recessed in fastener opening 264. In alternative embodiments, rivet head 272 may be button, pan, or cone shaped for example. As shown, rivet head 272 may have a width 284 greater than fastener slot 164.

Rivet 148 may have any suitable rivet body 268. In some embodiments, rivet body 268 may single expanding, or be double expanding to produce two bulges along its length. For example, rivet body 268 may have two expansion rings 288 to define a first expandable portion 292 between mandrel head 296 and the first expansion ring 288, and a second expandable portion 304 between the first and second expansion rings 288. Each expandable portion 304 may expand radially and engage with slot walls 192 and 196 of fastener slot 164 when mandrel 276 is drawn through rivet body 268.

Rivet 148 may have any suitable length 308. In the illustrated embodiment, rivet length 308 is sized to permit rivet 148 to be inserted into its final position in fastener opening 264 and fastener slot 164 prior to expanding rivet 148. For example, rivet length 308 may be less than or equal to the thickness of panel sidewall 120 and slot depth 220 of fastener slot 164 combined. It will be appreciated that rivet length 308 may be greater than this sum where, for example, rivet head 272 is intended protrude from the outside face 128 of panel sidewall 120.

Rivet body 268 may have any suitable width 310. As shown in FIG. 3B, an unexpanded width 310 of rivet body 268 may be equal to or less than slot height 226 of fastener slot 164. This may permit rivet 148 to be inserted into fastener slot 164 without unnecessary resistance. Preferably, an expanded width 310 of rivet body 268 is greater than a height 226 of fastener slot 164 so that rivet body 268 can engage fastener slot 164, as discussed in more detail below.

As shown in FIG. 3C, rivet body 268 may be expanded to engage with fastener slot 164 for permanently fastening perimeter extrusion 112 to panel 108. Slot upper and lower walls 192 and 196 of fastener slot 164 may have non-planar surface profiles to enhance engagement with rivet body 268 when expanded. For example, at least a portion of slot upper wall 192 and/or at least a portion of slot lower wall 196 may have a serrated interior surface 316. As used herein and in the claims, a surface is said to be “serrated” when the surface includes a plurality of tooth-like protrusions (i.e. 2 or more tooth-like protrusions). This is contrasted with a threaded opening which includes one or more helical threads instead of teeth. In the illustrated embodiment, both of the slot upper and lower walls 192 and 196 include a serrated interior surface 316 along the full depth 220 of fastener slot 164. In alternative embodiments, a serrated interior surface 316 may extend only partially between the slot outer and inner ends 204 and 208 on one or both of slot upper and lower walls 192 and 196.

As shown, serrated interior surface 316 may include a plurality of regularly spaced, symmetrically shaped, identical teeth 312. In alternative embodiments, spacing between teeth 312 may be patterned (e.g. increasing or decreasing) or irregular (e.g. random). In some embodiments, teeth 312 may be asymmetrically shaped. For example, teeth 312 may be sloped with a tip facing toward or away from slot outer end 204. In some embodiments, the plurality of teeth 312 may include a plurality of differently sized and/or shaped teeth 312. For example, the teeth on the serrated interior surface 316 of upper wall 192 may differ from the teeth on the serrated interior surface 316 of lower wall 196. Further, there may be a plurality of differently shaped and/or sized teeth 312 on the serrated interior surface 316 of the slot upper and/or lower walls 192, 196. Each tooth 312 may extend linearly along width 224 of fastener slot 164 in the direction of extrusion. As shown, serrated interior surface 316 and teeth 312 may extend the entire width 224 of fastener slot 164. Serrated interior surfaces 316 may include any suitable number of teeth. For example, serrated interior surfaces 316 may include between 2-200 teeth, or between 10-75 teeth. In the illustrated embodiment, each serrated interior surface 316 includes 12 teeth 312 for a combined 24 teeth in total for fastener slot 164.

Referring now to FIGS. 3C and 4, rivet body 268 may be formed of a flexible material (e.g. a malleable soft metal, such as aluminum) which may deform in compliance to the serrations on serrated interior surface 316 of the slot upper and lower walls 192 and 196 of fastener slot 164 when expanded. For example, each expanded portion 292 and 304 of rivet body 268 may expand in between the teeth 312 of fastener slot 164 thereby becoming indented with a serrated profile of its own, which interlocks with the serrations (i.e. teeth 312) of fastener slot 164. This interlocked mating between rivet body 268 and fastener slot 164 may provide a robust permanent connection between rivet 148 and fastener slot 164. In alternative embodiments, a screw (not shown) may be inserted through fastener opening 264 (FIG. 1) in panel sidewall 120 into fastener slot 164 of perimeter extrusion 112. In this case, the threads of the screw may engage with the teeth 312 of fastener slot 164 to form a secure connection.

Perimeter extrusion 112 may be formed in any suitable manner. In some embodiments, at least a portion of perimeter extrusion 112 is integrally formed, such as by casting or extrusion. Other portions of perimeter extrusion 112 may be connected in a suitable fashion such as by fasteners (e.g. screws, rivets, or nails), adhesives, or welds. In the illustrated embodiment, the entirety of perimeter extrusion 112 is formed by extrusion as a finished article. As shown, this may provide perimeter extrusion 112 with a constant cross-sectional profile along the entire width 232 (FIG. 1) of perimeter extrusion 112. In some cases, forming the entirety of perimeter extrusion 112 by extrusion may provide one or more of enhanced strength, improved consistency, and lower costs as compared with other manufacturing techniques.

It will be appreciated that serrated fastener slot 164 may permit permanent riveted assembly of panel assembly 100 without having to drill holes (or remove any material for that matter) from perimeter extrusions 112. This may mitigate the risk of scrap drillings scratching the outside face 128 of panel 108 during assembly, and may eliminate the labor required to drill into perimeter extrusions 112. In turn this may reduce material costs from ruined panels 108, reduce labor costs from drilling, and reduce assembly time.

While the above description provides examples of the embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. Accordingly, what has been described above has been intended to be illustrative of the invention and non-limiting and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto. The scope of the claims should not be limited by the preferred embodiments and examples, but should be given the broadest interpretation consistent with the description as a whole.

Claims

1. A perimeter extrusion for mounting a panel to a building wall, the panel having a panel front wall, and at least one panel sidewall extending along a periphery of the panel front wall, the perimeter extrusion comprising:

a panel engaging portion having a width to receive the extent of the at least one panel sidewall;

a fastener slot within the panel engaging portion and extending the width of the panel engaging portion, the fastener slot oriented to face the panel sidewall, the fastener slot having a height sized to receive a fastener, the fastener slot including a slot upper wall opposite and spaced apart from a slot lower wall by a slot inner wall connecting the slot upper and lower walls at the slot inner end, and a slot outer end defining a slot opening, each slot upper and lower wall has an interior face extending between the slot inner and outer ends, and at least a portion of at least one of the interior faces is serrated for engaging a fastener; and

an anchor engaging portion connected to the panel engaging portion having an anchor slot sized to receive an anchor flange of an anchor extrusion.

2. The perimeter extrusion of claim 1, wherein:

at least a portion of the interior face of both the slot upper and lower walls is serrated.

3. The perimeter extrusion of claim 1, wherein:

the entire interior face of the at least one of the interior faces is serrated.

4. The perimeter extrusion of claim 1, wherein:

the anchor slot comprises a slot upper wall opposite and spaced apart from a slot lower wall by a slot inner wall connecting the slot upper and lower walls at the slot inner end, and a slot outer end defining a slot opening.

5. The perimeter extrusion of claim 4, wherein:

the slot inner ends of the fastener and anchor slots are both positioned at an inner end of the perimeter extrusion.

6. The perimeter extrusion of claim 1 further comprising:

a filler strip engaging portion having a filler strip slot sized to receive a filler strip for covering an anchor extrusion.

7. The perimeter extrusion of claim 6, wherein:

the filler strip slot comprises a slot upper wall opposite and spaced apart from a slot lower wall by a slot inner wall connecting the slot upper and lower walls at the slot inner end, and a slot outer end defining a slot opening.

8. The perimeter extrusion of claim 6 wherein:

the filler strip slot comprises a slot upper wall opposite and spaced apart from a slot lower wall by a slot inner wall connecting the slot upper and lower walls at the slot inner end, and a slot outer end defining a slot opening;

the slot inner wall of the anchor slot meets the slot inner wall of the filler strip slot at a slot interface; and

a common slot dividing wall extending from the slot interface outwardly forms the slot upper wall of the anchor slot and the slot lower wall of the filler strip slot.

9. The perimeter extrusion of claim 1 wherein:

the panel engaging portion is positioned above the anchor engaging portion.

10. The perimeter extrusion of claim 4 wherein:

the slot upper wall of the anchor slot is positioned below and spaced apart from the slot lower wall of the fastener slot.

11. The perimeter extrusion of claim 1 wherein:

the perimeter extrusion is an integrally formed extruded article.

12. A kit for mounting a panel to a building wall, the panel having a panel front wall, and at least one panel sidewall extending along a periphery of the panel front wall, the kit comprising:

at least one perimeter extrusion, the perimeter extrusion comprising: a panel engaging portion having a width to receive the extent of the at least one panel sidewall; a fastener slot within the panel engaging portion and extending the width of the panel engaging portion, the fastener slot oriented to face the panel sidewall, the fastener slot having a height sized to receive a fastener having a fastener slot, the fastener slot including a slot upper wall opposite and spaced apart from a slot lower wall by a slot inner wall connecting the slot upper and lower walls at the slot inner end, and a slot outer end defining a slot opening, each slot upper and lower wall has an interior face extending between the slot inner and outer ends, and at least a portion of at least one of the interior faces is serrated; and an anchor engaging portion connected to the panel engaging portion having an anchor slot shaped to receive an anchor flange of an anchor extrusion; and

at least one rivet, the rivet having a rivet head and a rivet body, the rivet body having (i) an unexpanded size for insertion through a panel sidewall and the slot opening into the fastener slot of the perimeter extrusion, and (ii) an expanded size for engaging the serrated portion of the at least one interior face to prevent withdrawal of the rivet from the fastener slot.

13. The kit of claim 12, wherein the rivet body is made of malleable metal to be indented by teeth of the serrated portion when expanded.

14. The kit of claim 12, wherein the rivet is a blind rivet.

15. The kit of claim 12, wherein the rivet head is larger than a height of the slot opening.

16. The kit of claim 12, wherein the rivet body forms two bulges for twice engaging the serrated portion.

17. A method of making a panel assembly for securing to a building wall, the method comprising:

placing a perimeter extrusion against an inside face of a panel sidewall of a panel, the panel including a panel front wall, the panel sidewall extending along a perimeter of the panel front wall, and the panel sidewall including at least one fastener opening, the perimeter extrusion including (i) a panel engaging portion, the engaging portion having a width to receive the extent of the inside face of the panel sidewall, the panel engaging portion having a serrated fastener slot having a slot opening facing the panel sidewall, and the fastener slot extending the width of the perimeter extrusion, and (ii) an anchor engaging portion;

inserting a rivet body of a rivet into the serrated fastener slot through the fastener opening; and

expanding the rivet body into engagement with the serrated fastener slot to permanently fasten the perimeter extrusion to the panel sidewall.

18. The method of claim 17, wherein expanding the rivet body comprises interlocking the rivet body with teeth of the serrated fastener slot.

19. The method of claim 17, wherein expanding the rivet body comprises teeth of the serrated fastener slot forming mating indentations in the rivet body.

20. The method of claim 17, wherein the rivet is a blind rivet including a mandrel, and expanding the rivet body comprises drawing the mandrel into the rivet body.

21. The method of claim 17, wherein expanding the rivet body comprises forming two bulges in the rivet body, each bulge engaging the serrated fastener slot.