Wall attachment clip, wall panel system, and system and method for supporting wall panels

Abstract

A clip for attaching and supporting wall panels to a building (such as for an exterior building envelope), a wall panel system, and systems and methods for supporting wall panels is provided. The clip includes a main body portion, a first extension portion, a second extension portion, and a face portion. The clip is used with a system of interlocking vapor barrier wall panels to support the wall panels and affix them to a building frame without compromising the vapor barrier. Exterior faade panels can also be affixed to the clip and building frame without compromising the vapor barrier.

Claims

1. A system for attaching and supporting a wall panel to a building structure, said system comprising: a stud element of the building structure; a barrier comprised of a plurality of interlocking panels, wherein each panel includes at least one edge portion that overlaps with at least one edge portion of an adjacent panel; a first clip and a second clip; and a hat subgirt coupled to said first and second clips, wherein each of the first and second clips comprises: a main body portion having a first end and a second end opposite said first end; an extension portion having a first end located at said second end of said main body portion and extending away from the building structure in a direction substantially perpendicular to said main body portion; and a face portion located at a second end of said extension portion and extending in a direction such that said face portion and said main body portion are substantially parallel planes, wherein the interlocking panels form a vapor barrier/drain plane having a vapor barrier seal/drain plane seal along the overlapping edges; wherein said main body portion of said first clip is nested against a first panel and is affixed to said stud element of the building structure through a hole in said at least one edge portion of said first panel such that said at least one edge portion of an adjacent second panel overlaps said hole in said first panel, such that said hole in said first panel is covered so as to maintain the vapor barrier seal, wherein said extension portion of said first clip extends between and past said first and second panels, wherein said main body portion of said second clip is nested against said second panel and is affixed to said stud element of the building structure through a hole in said at least one edge portion of said second panel such that said at least one edge portion of an adjacent third panel overlaps said hole in said second panel, such that said hole in said second panel is covered so as to maintain the vapor barrier seal, wherein said extension portion of said second clip extends between and past said second and third panels, wherein said respective face portions of said first and second clips are displaced from an outer surface of said first, second, and third panels, and wherein respective face portions and respective second ends of said extension portions of said first and second clips are positioned inside said hat subgirt.

2. The system as claimed in claim 1, further comprising: an exterior faade affixed to the face portion of the clip such that the drain plane is not penetrated and the drain plane seal remains intact.

3. The system as claimed in claim 1, wherein said clip is affixed to said stud element of the building structure via an anchor that penetrates the main body portion of the clip, said edge portion of the first panel, and said stud element of the building structure.

4. The system as claimed in claim 2, further comprising: a pressure equalizing void located between said vapor barrier and said exterior faade.

5. The system as claimed in claim 1, further comprising: a sealant connects the edge of said first panel to the edge of said adjacent panel to form said vapor barrier seal.

6. A method of attaching and supporting a wall panel to a building structure, said method comprising: affixing a first clip to a stud element of the building structure through a hole in an edge portion of a first panel; interlocking said first panel with an adjacent panel such that said hole in the edge portion of the first panel is covered by an overlapping portion of said adjacent panel, the interlocking, overlapping first and adjacent panels forming a vapor barrier/drain plane having a vapor barrier seal/drain plane seal between said first panel and said adjacent panel; affixing a second clip to a stud element of the building structure through a hole in an edge portion of said adjacent panel; and affixing a hat subgirt to said first and second clips, wherein said face portions and said second ends of said second extension portions of said first and second clips are positioned inside said hat subgirt.

7. The method as claimed in claim 6, further comprising affixing an exterior faade to said hat subgirt such that the vapor barrier seal remains intact and the drain plane not penetrated.

8. The method as claimed in claim 6, wherein said first and second clips each comprise: a main body portion having a first end and a second end opposite said first end; a second extension portion having a first end located at said second end of said main body portion and extending away from the building structure in a direction substantially perpendicular to the main body portion; and a face portion located at a second end of said second portion and extending in a direction such that said face portion and said main body portion are substantially parallel planes.

9. The method as claimed in claim 6, further comprising affixing an exterior faade to said hat subgirt such that the vapor barrier seal remains intact and the drain plane not penetrated.

Description

DESCRIPTION OF THE DRAWINGS

(1) Preferred embodiments of the invention, illustrative of the best mode in which the applicant has contemplated applying the principles, are set forth herein and are shown in the drawings.

(2) FIG. 1 shows a cross-sectional view of a traditional multi-component wall construction of the prior art.

(3) FIG. 2 shows a cross-sectional view of a modified version of the traditional multi-component wall construction of the prior art.

(4) FIG. 3 shows a cross-sectional view of another modified version of the traditional multi-component wall construction of the prior art.

(5) FIG. 4 shows a cross-sectional view of an embodiment of a system of the instant invention.

(6) FIG. 5 shows various views of a clip of an embodiment of the instant invention. FIG. 5-A is a perspective view. FIG. 5-B is a top view. FIG. 5-C is a front view. FIG. 5-D is a side view.

(7) FIG. 6 shows a cross-sectional view of another embodiment of a system of the instant invention, similar to that of FIG. 4, but with a one piece bracket connecting the subgirt to the faade panels.

DETAILED DESCRIPTION

(8) As required, a detailed embodiment of the present invention is disclosed herein; however, it is to be understood that the disclosed embodiment is merely exemplary of the principles of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

(9) As shown in FIGS. 4 and 5, an embodiment of a clip 100 and of a system of the instant invention utilizing clip 100 is provided. The clip 100 is used for attaching and supporting a wall panel to a building structure. The clip 100 includes a main body portion 102. Located at opposing ends of the main body portion 102, the clip 100 includes a first extension or flange portion 104 and a second extension portion 106. The first extension portion 104 and the second extension portion 106 both extend outward away from the main body portion 102 in opposite directions, with both being substantially perpendicular to the main body portion 102. At the end of the second extension portion 106, the end opposite the main body portion 102, is located a face portion 108. The face portion 108 extends outward and away from the second extension portion 106 such that it is substantially parallel with the main body portion 102, yet offset by the length of the second extension portion 106.

(10) In the embodiment shown in FIG. 4, the first extension or flange portion 104 is used to pierce an edge 134 of a vapor barrier panel 130, such as the tongue-and-groove feature shown and described in the vapor barrier panel system of the '181 patent and/or Exhibits B, C and D of U.S. provisional patent application No. 61/509,109. The clip 100 is secured to a building framing 109 with an anchor 107 through the main body portion 102. The vapor barrier 130 is not compromised because the anchor 107 and clip 104 penetrate the panel 130a at an edge 134a that is sealed or covered by the edge 134b an adjacent vapor barrier panel 130b.

(11) The face portion 108 is used to affix an exterior faade 160 to the exterior of the building. With the exterior faade 160 affixed to the face portion 108 of the clip 100, the exterior faade 160 is structurally supported by the building frame 109 without compromising the vapor barrier 130.

(12) In some embodiments, the main body portion 102 includes one or more pre-drilled hole(s) 103. In an embodiment with pre-drilled holes 103 in the main body portion 102, the clip 100 is anchored to the building framing 109 through one or more of the pre-drilled hole(s) 103.

(13) In some embodiments, the face portion 108 includes one or more pre-drilled hole(s) 103. In an embodiment with pre-drilled holes 103 in the face portion 108, the exterior faade 160 is affixed to the clip 100 through the one or more pre-drilled hole(s) 103 in the face portion 108.

(14) In some embodiments, the first extension portion 104 includes one or more tooth 105 sized and shaped to penetrate a portion of foam insulation that is exposed in a vapor barrier panel 130 along one of the edges 134. In some embodiments, the clip 100 is a single-piece, unibody apparatus. In some embodiments, the clip 100 is made out of 14 gauge galvanized steel.

(15) As used throughout this specification, the term substantially perpendicular includes any angle between 80 and 100 degrees. As used throughout this specification, the term substantially parallel includes any two planes wherein the smallest angle between the two planes is 15 degrees or less. For example:

(16) In some embodiments, the first extension portion 104 is substantially perpendicular to the main body portion 102, but is slightly turned down, such that the angle between the main body portion 102 and the first extension portion 104 is slightly less than a 90 degree angle, or about 85 degrees. In some embodiments, the second extension portion 106 is substantially perpendicular to the main body portion 102, but is slightly turned down, such that the angle between the main body portion 102 and the second extension portion 106 is slightly greater than a 90 degree angle, or about 95 degrees. In an embodiment where the angle between the first extension portion 104 and the main body portion 102 is about 85 degrees and the angle between the second extension portion 106 and the main body portion 102 is about 95 degrees, the first extension portion 104 is substantially parallel to the second extension portion 106 even though they vary from being perfectly parallel by about 10 degrees.

(17) FIG. 4 shows one embodiment of a multiple piece horizontal support bracket for faade panels. As shown in FIG. 4, a system for attaching and supporting a wall panel to a building structure is provided. The system does not compromise the vapor barrier of the building. The system includes a clip 100 for attaching and supporting a wall panel to a building structure. One example of the clip is described above and shown in FIG. 5. The system of FIG. 4 further includes a stud element 109 of a building structure. The system further includes a vapor barrier 130. The vapor barrier is formed of a plurality of interlocking panels 130a and 130b. Each panel 130a includes at least one edge portion 134a that overlaps with at least one edge portion 134b of an adjacent panel 130b.

(18) The clip 100 is affixed to the stud element 109 of the building structure through a hole 136 in the edge portion 134a of a first panel 130a. The edge 134b of an adjacent panel 130b interlocks with the edge 134a of the first panel 130a such that the hole 136 through which the clip 100 is anchored to the stud 109 is sealed and the vapor barrier 130 is not compromised. In the vapor barrier panel system of the '181 patent and/or Exhibits B, C and D of U.S. provisional patent application No. 61/509,109, the panels 130a and 130b include interlocking tongue-and-groove edges.

(19) As is shown in FIG. 4, a hat subgirt 150 is attached to the clip 100 by extending a screw 155 through the face portion 108 of the clip 100. The exterior faade panels 160a and 160b are then attached to the subgirt 150 via other screws 155a. The clip 100 is located at the top tongue section 134a of an insulated steel sandwich vapor barrier panel 130a that includes a tongue and groove interlocking system with adjacent vapor barrier panels 130b. A sealant material 137 is located in the tongue and groove as shown in FIG. 4. As is shown in FIG. 4, the downward central flange portion 104 of the clip 100 extends into the foam portion 134a of the vapor barrier panel 130a at a location in which the foam is exposed (i.e. the steel sheeting does not continue around the entire tongue portion of the top of the panel). The anchor 107 to attach the clip 100 extends through the steel sheet on both the exterior and interior surfaces of the vapor barrier panel 130a and into the stud 109.

(20) As further shown in FIG. 4, an interior section 163a of the support bracket 163 is screwed to the subgirt 150. Filler strip 163b be is screwed to section 163a, and top section 163c is connected to filler strip 163b via an overlapping tongue and groove relationship. It will be appreciated that in alternative embodiments, a single piece bracket, or even direct connection of faade panels 160 to the subgirt 150 may be utilized. Furthermore, it will be appreciated that any type of faade may be attached utilizing the system of the instant invention.

(21) Referring to FIG. 6, another embodiment of a system of the instant invention, similar to that of FIG. 4, is shown with a one piece bracket connecting the subgirt to the faade panels. As is shown in FIG. 6, a hat subgirt 150 is attached to the clip 100 by extending a screw 155 through the face portion 108 of the clip 100. The exterior faade panels 160a and 160b are then attached to the subgirt 150 via screws 155a (not shown in FIG. 6). The clip 100 is located at the top tongue section 134a of an insulated steel sandwich vapor barrier panel 130a that includes a tongue and groove interlocking system with adjacent vapor barrier panels 130b. A sealant material may be located in the tongue and groove in the manner shown in FIG. 4. The downward central flange portion 104 of the clip 100 extends into the foam portion 134a of the vapor barrier panel 130a at a location in which the foam is exposed (i.e. the steel sheeting does not continue around the entire tongue portion of the top of the panel). The anchor 107 to attach the clip 100 extends through the steel sheet on both the exterior and interior surfaces of the vapor barrier panel 130a and into the stud 109. As further shown in FIG. 6, one-piece support bracket 163 is screwed to the subgirt 150. Bracket 163 shown in FIG. 6 is shaped as a unitary piece to receive exterior faade panels 160a and 160b and includes a filler surface similar to the filler strip 163b of FIG. 4 as part of the unitary piece. In the embodiment shown in FIG. 6, a separate top section fits into the one piece bracket 163 through a tongue and groove relationship. Panel 160b is connected to the top section, while panel 160a is connected to bracket 163 directly. It will be appreciated that in alternative embodiments, or even direct connection of faade panels 160 to the subgirt 150 may be utilized. Furthermore, it will be appreciated that any type of faade may be attached utilizing the system of the instant invention.

(22) In some embodiments of the system, an exterior faade 160 is affixed to an outer portion 108 of the clip 100 such that the integrity of the vapor barrier 130 is not compromised. In some embodiments, a portion 104 of the clip 100 penetrates the edge portion 134a of the first panel 130a. In some embodiments, a pressure equalizing void 190 is maintained between the vapor barrier 130 and the exterior faade 160.

(23) Methods for supporting wall panels are provided. The methods described herein do not compromise the vapor barrier of the wall. The method includes affixing a main body portion 102 of a clip 100 to a stud element 109 of the building structure through a hole 136 in an edge portion 134a of a first panel 130a and interlocking the first panel 130a with an adjacent panel 130b such that the hole 136 in the edge portion 134a of the first panel 130a is covered by an overlapping portion 134b of the adjacent panel 130b. The interlocking and overlapping first 130a and adjacent 130b panels form a vapor barrier 130 that is not compromised by the clip 100 which is used to support the vapor barrier panels 130a and 130b and affixed to the stud 109 of the building frame. In some embodiments, the method further includes penetrating the main body portion 102 of the clip 100, the hole 136 in the edge portion 134a of the first panel 130a, and the stud element 109 of the building structure with an anchor 107 to secure the clip 100 and panel 130a to the building structure. In some embodiments, the method further includes affixing an exterior faade 160 to an outer portion 108 of the clip 100 without compromising the vapor barrier 130.

(24) In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration is by way of example, and the scope of the inventions is not limited to the exact details shown or described.

(25) Although the foregoing detailed description has been described by reference to an exemplary embodiment, and the best mode contemplated for carrying out the present inventive concept has been shown and described, it will be understood that certain changes, modification or variations may be made in embodying the above invention, and in the construction thereof, other than those specifically set forth herein, may be achieved by those skilled in the art without departing from the spirit and scope of the invention, and that such changes, modification or variations are to be considered as being within the overall scope of the present invention. Therefore, it is contemplated to cover the present invention and any and all changes, modifications, variations, or equivalents that fall within the true spirit and scope of the underlying principles disclosed and claimed herein. Consequently, the scope of the present invention is intended to be limited only by the attached claims, all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

(26) Having now described the features, discoveries and principles of the invention, the manner in which the invention is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.

(27) It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

(28) Finally, it will be appreciated that the purpose of the annexed Abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. Accordingly, the Abstract is neither intended to define the invention or the application, which only is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.