US20220251836A1

US20220251836A1 - Cross laminated timber wall panel system

Info

Publication number: US20220251836A1
Application number: US17/590,055
Authority: US
Inventors: Mark Mathey; Jeremy Thomas DeWitt; Ondrei Stefan Poliak; David P. Markman; Daniel Delisle
Original assignee: Mercer Mass Timber LLC
Current assignee: Mercer Mass Timber LLC
Priority date: 2018-11-13
Filing date: 2022-02-01
Publication date: 2022-08-11
Also published as: US20200149276A1

Abstract

In one aspect, a wall panel is provided that includes a cross laminated timber panel, a first extrusion, and a second extrusion. The cross laminated timber panel includes a top side, a bottom side, a first side, and a second side. The panel also includes a notch in the bottom side and a T-flange on the top side. A wall system is provided comprising a plurality of wall panels. A method of installing the wall panel system is also provided.

Description

FIELD OF INVENTION

The present invention relates generally to the art of exterior walls of buildings, and more specifically to a wall panel, a wall panel system, and a method of installation thereof, for buildings.

BACKGROUND

Cross-Laminated Timber or CLT is a pre-fabricated, engineered wood building material with unique and often superior building, aesthetic, environmental, and cost attributes. CLT wood panels are made by pressing perpendicular layers of lumber together with a layer of formaldehyde-free adhesive. The fusion of orthogonal wood layers is what gives CLT biaxial strength, durability, and stability. CLT can serve as a system-based approach for floors, walls, and roofs to form a high-performance, sustainable, and beautiful mass timber building of virtually any type.
CLT requires less energy to produce than other building materials such as steel and concrete and is made from renewable material. CLT panels may be prefabricated and are also lighter than panels made from other material such as steel, thereby reducing design costs of the building. CLT panels may be connected together to create the floor, wall, or roof.
Most wall panels of a curtain wall system are constructed from glass and aluminum. Not only are these materials expensive, they limit the design of the wall panel, and thus, the wall system.

SUMMARY

In one aspect, a wall panel is provided that includes an infill component, a first extrusion, and a second extrusion. The infill component includes a top side, a bottom side, a first side, and a second side. The panel also includes a notch in the bottom side and a T-flange on the top side. A wall system is provided comprising a plurality of connected wall panels. A method of installing the wall panel system is also provided.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description will be better understood when read in conjunction with the appended drawings. For the purpose of illustration, there is shown in the drawings different embodiments. It should be understood, however, that the teachings are not limited to the precise wall panel system arrangement shown.

FIG. 1 is a front, left perspective view of a first embodiment of a wall panel.

FIG. 2 is an exploded view of an infill component.

FIG. 3 is a front, left perspective view of a second wall panel installed with a first wall panel.

FIG. 4 is a front, left perspective view of a third wall panel installed with the first wall panel and the second wall panel of FIG. 3.

FIG. 5 is a front, left perspective view of a fourth wall panel installed with the first wall panel, the second wall panel, and the third wall panel of FIG. 4.

FIG. 6 is a front, left perspective view of the intersection of the wall panel system showing the seals, continuous splice plates, and the patch plate.

FIG. 7 is a first cross-section view of adjacent wall panels of the wall panel system.

FIG. 8 is a second cross-section view of adjacent wall panels of the wall panel system.

FIG. 9 is a third cross-section view of adjacent wall panels of the wall panel system.

FIG. 10 is a first cross-section view of stacked wall panels of the wall panel system.

FIG. 11 is a second cross-section view of stacked wall panels of the wall panel system.

FIG. 12 is a third cross-section view of stacked wall panels of the wall panel system.

FIG. 13 is a flow chart of a method of installing the wall panel system.

DETAILED DESCRIPTION

A wall panel is provided that comprises a cross laminated timber panel. The cross laminated timber panel allows various materials and components to be added to the wall panel which provides flexibility of the wall panel design as well as the design of the wall system. The wall panel includes an infill component which includes a CLT panel. The wall panel also includes a first extrusion and a second extrusion. The panel also includes a notch in the bottom side and a T-flange on the top side. The extrusions, the notch, and the T-flange allow the wall panel to easily and efficiently connect to other wall panels. A plurality of wall panels can connect together to create a wall system.
FIG. 1 is a front, left perspective view of a first embodiment of a wall panel 100. The wall panel 100 may be load bearing and may be non-load bearing. The wall panel 100 comprises an infill component 200. The infill component 200 includes a top side 310, a bottom side 320, a first side 330, and a second side 340 (not visible in FIG. 1). Moreover, the infill component 200 includes a notch 400 in the bottom side 320 and a T-flange 500 on the top side 310. The wall panel 100 also includes a first extrusion 600 a and a second extrusion 600 b.
As shown in FIG. 1, the first extrusion 600 a is attached to the second side 340 and the second extrusion 600 b is attached to the top side 310. Alternatively, the first extrusion 600 a may be attached to the first side 330 and the second extrusion 600 b attached to the top side 310; the first extrusion 600 a may be attached to a first side 330 and the second extrusion 600 b attached to the bottom side 320; or the first extrusion 600 a may be attached to a second side 340 and the second extrusion 600 b attached to the bottom side 320.
The wall panel 100 may also include a third extrusion and a fourth extrusion (not shown). In this embodiment, the first extrusion 600 a is attached to the first side 330, the second extrusion 600 b is attached to the top side 310, the third extrusion is attached to the second side 340, and the fourth extrusion is attached to the bottom side 320.
Each extrusion 600 a, 600 b may comprise a U-channel with an attachment flange, as shown in FIG. 1. Alternatively, the extrusions 600 a, 600 b may comprise two or more connected angles. The U-channel may also include seals or gaskets 610, continuous splice plates 620, and closed cell foam (not shown). The seals or gaskets 610 may be silicone gaskets, and the splice plates 620 may be aluminum. The extrusions 600 a, 600 b and T-flange 500 may be galvanized steel, aluminum, vinyl, or other suitable rigid material. The extrusions 600 a, 600 b, the T-flange 500, and the notch 400 allow the wall panel 100 to connect with adjacent wall panels 100. The extrusions 600 a, 600 b connect with the extrusions of an adjacent wall panel 100. The T-flange 500 connects with the notch 400 of an adjacent wall panel 100. The notch 400 connects with the T-flange 500 of an adjacent wall panel 100.
FIG. 2 is an exploded view of an infill component 200. Referring to FIG. 2, the infill component 200 includes a cross laminated timber panel 210. The cross laminated timber panel 210 may include a vapor barrier adhered to the surface to prevent water vapor from diffusing into the cross laminated timber panel 210. The infill component 200 may also include insulation 220. The insulation may include two layers of mineral wool. The infill component 200 may also include a terra cotta panel 250. The terra cotta panel 250 may be combined with other materials and may be customized to create a variety of exterior designs of buildings. The terra cotta panel 250 is connected to the insulation 220 and cross laminated timber panel 210 via hat channels 230 and horizontal supports with terra cotta clips 240. The cross laminated timber panel 210 may also include window flashing 260, metal panels 270, windows 280, and an aluminum extrusion 290, as shown in FIG. 2. The aluminum extrusion 290 protects the end-grain.
A plurality of connected wall panels 100 makes up a wall panel system 700. The wall panels 100 mate with adjacent wall panels 100. Each wall panel 100 of the wall panel system 700 includes the features, components, and embodiments of a wall panel 100 previously discussed in detail. The wall panel system 700 includes at least two connected wall panels 100. The wall panels 100 connect via the first extrusions 600 a or the second extrusions 600 b, T-flange 500 and notch 400.
FIG. 3 is a front, left perspective view of a second wall panel 100 b installed with a first wall panel 100 a. As shown in FIG. 3, a first wall panel 100 a adjacently mates with a second wall panel 100 b. The first wall panel 100 a mates with the second wall panel 100 b via the first extrusion 600 a of the first wall panel 100 a and the first extrusion 600 a of the second wall panel 100 b. A splice plate 620 extends between the first extrusion 600 a of the first wall panel 100 a and the first extrusion 600 a of the second wall panel 100 b (not visible in FIG. 3). A splice plate 620 may also be inserted in the second extrusion 600 b of the first wall panel 100 a and the second extrusion 600 b of the second wall panel 100 a to connect to a second extrusion 600 b of a third wall panel 100 c and a second extrusion 600 b of a fourth wall panel 100 d respectively. The connections to the third wall panel 100 c and the fourth wall panel 100 d are discussed in further detail below and shown in FIGS. 4 and 5. The wall panel system 700 may also include a patch plate 630 to weatherproof the joint between the first wall panel 100 a and the second wall panel 100 b. Preferably, the patch plate 630 is an extruded aluminum patch plate.
FIG. 4 is a front, left perspective view of a third wall panel 100 c installed with the first wall panel 100 a and the second wall panel 100 b of FIG. 3. Referring to FIG. 4, the wall panel system 700 may also include a third wall panel 100 c stacked on the first wall panel 100 a. The notch 400 of the third wall panel 100 c mates with the T-flange 500 of the first wall panel 100 a. Moreover, the second extrusion 600 b of the third wall panel 100 c mates with the second extrusion 600 b of the first wall panel 100 a. The splice plate 620 in the second extrusion 600 b of the first wall panel 100 a, previously shown in FIG. 3, extends between the second extrusion 600 b of the first wall panel 100 a and the second extrusion 600 b of the third wall panel 100 c (not visible in FIG. 4). A splice plate 620 may also be inserted in the first extrusion 600 a of the third wall panel 100 c to connect with the first extrusion 600 a of the fourth wall panel 100 d.
FIG. 5 is a front, left perspective view of a fourth wall panel 100 d installed with the first wall panel 100 a, the second wall panel 100 b, and the third wall panel 100 c of FIG. 4. As shown in FIG. 5, the wall panel system 700 may include a fourth wall panel 100 d. The fourth wall panel 100 d connects with the second wall panel 100 b and the third wall panel 100 c. The T-flange 500 of the second wall panel 100 b mates with the notch 400 of the fourth wall panel 100 d. Moreover, the second extrusion 600 b of the second wall panel 100 b mates with the second extrusion 600 b of the fourth wall panel 100 d, and the first extrusion 600 a of the fourth wall panel 100 d mates with the first extrusion 600 a of the third wall panel 100 c. As shown in FIG. 5, a splice plate 620 extends between the second extrusion 600 b of the second wall panel 100 b and the second extrusion 600 b of the fourth wall panel 100 d. A splice plate 620 also extends between the first extrusion 600 a of the third wall panel 100 c and the first extrusion 600 a of the fourth wall panel 100 d.
Mating the extrusions 600 a, 600 b of the four wall panels 100 a-d forms a joint or intersection in the shape of a “cruciform” or“+” sign. FIG. 6 is a front, left perspective view of the intersection of the wall panel system 700 showing the seals or gaskets 610, continuous splice plates 620, and the patch plate 630. FIG. 6 shows the seals or gaskets 610, splice plates 620, and patch plate 630 of the “cruciform.” The seals or gaskets 610, the splice plates 620, and the patch plate 630 weatherproof the “cruciform” or“+” sign joint of the wall panel system 700.
Although an example four wall panel 100 a-d wall panel system 700 is illustrated, the wall panel system 700 may include additional wall panels 100. The notches 400 and second extrusion 600 b of any additional rows of wall panels 100 mate with the T-flange 500 and second extrusion 600 b of the previous row of wall panels 100. Moreover, the first extrusions 600 a of any additional adjacent wall panels 100 mate with the first extrusions 600 a of the previous adjacent wall panels 100.
FIG. 7 is a first cross-section view of adjacent wall panels 100 of the wall panel system 700. FIG. 7 depicts the vertical mated joint between adjacent wall panels 100. The first extrusions 600 a are connected to the wall panels 100. The first extrusions 600 a may be screwed into the wall panel 100, adhered to the wall panel 100, or otherwise connected. The U-channel may be connected to the attachment flange via staggered fasteners. The U-channel and attachment flange joint may be sealed with silicone to prevent water from entering the joint. The first extrusions 600 a may include open cell foam to act as a thermal break or thermal barrier. The splice plate 620 may slide between the seals or gaskets 610 to allow for different distances between adjacent wall panels 100 and to allow expansion and contraction of the wall panels 100. The ends of the splice plate 620 may be thicker to prevent the splice plate 620 from slipping through the seals or gaskets 610 and becoming disengaged from the first extrusions 600 a. FIG. 7 shows an undisplaced position of adjacent wall panels 100. The distance between adjacent wall panels 100 at this position may be approximately 1.5″.
As further illustrated in FIGS. 8 and 9, the first extrusions 600 a and splice plate 620 connection permits a varying degree of displacement between adjacent wall panels 100. FIG. 8 depicts adjacent wall panels 100 with minimal displacement. While, FIG. 9 depicts adjacent wall panels 100 at the maximum displacement.
FIG. 8 is a second cross-section view of adjacent wall panels 100 of the wall panel system 700. FIG. 8 shows the wall panels 100 and joint of FIG. 7. However, FIG. 8 depicts the adjacent wall panels 100 in a closer or closed position. The ends of the splice plate 620 are touching the backs of the U-shape channel of the extrusions 600 a. At this position, the adjacent wall panels 100 are the closest together representing a minimum joint dimension. The distance between adjacent wall panels 100 at this position may be approximately 0.29″.
FIG. 9 is a third cross-section view of adjacent wall panels 100 of the wall panel system 700. FIG. 9 shows the wall panels 100 and joint of FIG. 7 and FIG. 8. However, FIG. 9 depicts the adjacent wall panels 100 in a farther or open position. The ends of the splice plate 620 are against the seals or gaskets 610. At this position, the adjacent wall panels 100 are the farthest apart representing a maximum joint dimension. The distance between adjacent wall panels 100 at this position may be approximately 2.332″.
FIG. 10 is a first cross-section view of stacked wall panels 100 of the wall panel system. FIG. 10 depicts a cross-section view of the mated horizontal joint between stacked wall panels 100. The second extrusions 600 b may be screwed into the wall panel 100, adhered to the wall panel 100, or otherwise connected. The U-channel may be connected to the attachment flange via staggered fasteners. The U-channel and attachment flange joint may be sealed with silicone to prevent water from entering the joint. The second extrusions 600 b may include open cell foam to act as a thermal break or thermal barrier. The splice plate 620 may slide between the seals or gaskets 610 to allow for different distances between stacked wall panels 100 and to allow expansion and contraction of the wall panels 100. The ends of the splice plate 620 may be thicker to prevent the splice plate 620 from slipping through the seals or gaskets 610 and becoming disengaged from the second extrusions 600 b. FIG. 10 shows an undisplaced position of stacked wall panels 100. The distance between stacked wall panels 100 at this position may be approximately 0.65″.
As further illustrated in FIGS. 11 and 12, the second extrusions 600 b and splice plate 620 connection and the T-flange 500 and notch 400 connection permits a varying degree of displacement between stacked wall panels 100. FIG. 11 depicts stacked wall panels 100 with minimal displacement. While, FIG. 12 depicts stacked wall panels 100 at a greater displacement.
FIG. 11 is a second cross-section view of stacked wall panels 100 of the wall panel system 700. FIG. 11 shows the wall panels 100 and horizontal joint of FIG. 10. However, FIG. 11 depicts the stacked wall panels 100 in a closer or closed position. The ends of the splice plate 620 are slid further into the U-channels of the second extrusions 600 b. The T-flange 500 is also further inserted in the notch 400 of the stacked wall panel 100. At this position, the stacked wall panels 100 are the closest together representing a minimum joint dimension. The distance between stacked wall panels 100 at this position may be approximately 0.312″.
FIG. 12 is a third cross-section view of stacked wall panels 100 of the wall panel system 700. FIG. 12 shows the same wall panels 100 and horizontal joint of FIG. 10 and FIG. 11. However, FIG. 12 depicts the stacked wall panels 100 in a farther or open position. The ends of the splice plate 620 are close to the seals or gaskets 610. Additionally, the T-flange 500 is closer to the opening of the notch 400 in the open position. At this position, the stacked wall panels 100 are the farthest apart representing a maximum joint dimension. The distance between stacked wall panels 100 at this position may be approximately 0.988″.
FIG. 13 is a flow chart of a method 1300 of installing the wall panel system. The method of installing an example four wall panel 100 a-d wall panel system 700 can be carried out according to the method 1300 described in FIG. 13 and described below.
In step 1310, the components of a wall panel system 700, as described above, are received. In step 1320, the first wall panel is installed. In step 1340, the second wall panel 100 b is placed adjacent to the first wall panel 100 a by mating the first extrusion 600 a of the second wall panel 100 b with the first extrusion 600 a of the first wall panel 100 a. In step 1380, the third wall panel 100 c is stacked on the first wall panel 100 a by mating the notch 400 and second extrusion 600 b of the third wall panel 100 c with the T-flange 500 and second extrusion 600 b of the first wall panel 100 a respectively. In step 1400, the fourth wall panel 100 d is stacked on the second wall panel 100 b by mating the notch 400 and second extrusion 600 b of the fourth wall panel 100 d with the T-flange 500 and second extrusion 600 b of the second wall panel 100 b respectively. The fourth wall panel 100 d is also adjacently connected to the third wall panel 100 c by mating the first extrusion 600 a of the fourth wall panel 100 d with the first extrusion 600 a of the third wall panel 100 c.
The method 1300 may also include step 1330 of installing a first splice plate 620 in the first extrusion 600 a of the first wall panel 100 a prior to placing the second wall panel 100 b.
The method 1300 may also include step 1350 of installing a second splice plate 620 in the second extrusion 600 b of the first wall panel 100 a prior to stacking the third wall panel 100 c.
The method 1300 may also include step 1360 of installing a third splice plate 620 in the second extrusion 600 b of the second wall panel 100 b prior to stacking the third wall panel 100 c and the fourth wall panel 100 d.
The method 1300 may also include step 1370 of installing a patch plate 630 at the intersection of the first splice plate 620, the second splice plate 620, and the third splice plate 620 prior to stacking the third wall panel 100 c.
The method 1300 may also include step 1390 of installing a fourth splice plate 620 in the first extrusion 600 a of the third wall panel 100 c prior to stacking the fourth wall panel 100 d.
Having thus described in detail a preferred selection of embodiments of the present invention, it is to be appreciated and will be apparent to those skilled in the art that many physical changes could be made to the wall panel, the wall panel system, and the installation thereof, without altering the inventive concepts and principles embodied therein. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore to be embraced therein.

Claims

What is claimed is:

1. A wall system comprising:

at least four cross laminated timber panels, each cross laminated timber panel including a top side, a bottom side, a first side, a second side, a notch in the bottom side, a T-flange on the top side, a first extrusion, and a second extrusion;

wherein the first extrusion and the second extrusion are each a U-channel with an attached flange a first of the at least four cross laminated timber panels including the first extrusion attached to the first side and the second extrusion attached to the top side;

a second of the at least four cross laminated timber panels including the first extrusion attached to the second side and the second extrusion attached to the top side;

a third of the at least four cross laminated timber panels including the first extrusion attached to the first side and the second extrusion attached to the bottom side, and

a fourth of the at least four cross laminated timber panels including the first extrusion attached to the second side and the second extrusion attached to the bottoms side;

the first extrusion of the first of the at least four cross laminated timber panels mating with the first extrusion of the second of the at least four cross laminates timber panels;

the first extrusion of the third of the at least four cross laminated timber panels mating with the first extrusion of the fourth of the at least four cross laminated timber panels;

the second extrusion of the third of the at least four cross laminated timber panels mating with the second extrusion of the first of the at least four cross laminated timber panels;

the notch of the third of the at least four cross laminated timber panels mating with the T-flange of the first of the at least four cross laminated timber panels;

the second extrusion of the fourth of the at least four cross laminated timber panels mating with the second extrusion of the second of the at least four cross laminated timber panels; and

the notch of the fourth of the at least four cross laminated timber panels mating with the T-flange of the second of the at least four cross laminated timber panels.

2. The wall system of claim 1, wherein the U-channel includes a seal.

3. A wall system comprising:

a first of the at least four cross laminated timber panels including the first extrusion attached to the first side and the second extrusion attached to the top side;

the first extrusion of the first of the at least four cross laminated timber panels mating with the first extrusion of the second of the at least four cross laminated timber panels;

the notch of the fourth of the at least four cross laminated timber panels mating with the T-flange of the second of the at least four cross laminated timber panels, and

a first continuous splice plate between the first extrusion of the first of the at least four cross laminated timber panels and the first extrusion of the second of the at least four cross laminated timber panels;

a second continuous splice plate between the second extrusion of the first of the at least four cross laminated timber panels and the second extrusion of the third of the at least four cross laminated timber panels;

a third continuous splice plate between the second extrusion of the second of the at least four cross laminated timber panels and the second extrusion of the fourth of the at least four cross laminated timber panels; and

a fourth continuous splice plate between the first extrusion of the third of the at least four cross laminated timber panels and the first extrusion of the fourth of the at least four cross laminated timber panels.

4. The wall system of claim 3 further including a patch plate at an intersection of the at least four cross laminated timber panels.

5. A method of installing a wall system comprising:

providing at least four wall panels, each wall panel including a cross laminated timber panel including a top side, a bottom side, a first side, a second side, a notch in the bottom side, a T-flange on the top side, a first extrusion, and a second extrusion, wherein the first extrusion and the second extrusion are each a U-channel with an attachment flange, a first of the at least four cross laminated timber panels including the first extrusion attached to the first side and the second extrusion attached to the top side, a second of the at least four cross laminated timber panels including the first extrusion attached to the second side and the second extrusion attached to the top side, a third of the at least four cross laminated timber panels including the first extrusion attached to the first side and the second extrusion attached to the bottom side, and a fourth of the at least four cross aminated timber panels including the first extrusion attached to the second side and the second extrusion attached to the bottom side;

installing the first of the at least four cross laminated timber panels;

installing the second of the at least four cross laminated timber panels adjacent to the first of the at least four cross laminated timber panels by connecting the first extrusion of the second of the at least four cross laminated timber panels mating with the first extrusion of the first of the at least four cross laminated timber panels;

installing the third of the at least four cross laminated timber panels on the first of the at least four cross laminated timber panels by connecting the second extrusion of the third of the at least four cross laminated timber panels with the second extrusion of the first of the at least four cross laminated timber panels and inserting the T-flange of the first of the at least four cross laminated timber panels into the notch of the third of the at least four cross laminated timber panels; and

installing the fourth of the at least four cross laminated timber panels on the second of the at least four cross laminated timber panels by connecting the second extrusion of the fourth of the at least four cross laminated timber panels with the second extrusion of the second of the at least four cross laminated timber panels, inserting the T-flange of the second of the at least four cross laminated timber panels into the notch of the fourth of the at least four cross laminated timber panels, and connecting the first extrusion of the fourth of the at least four cross laminated timber panels.

6. The method of claim 5, wherein the U-channel includes a seal.

7. A method of installing a wall system comprising:

providing at least four wall panels, each wall panel including a cross laminated timber panel including a top side, a bottom side, a first side, a second side, a notch in the bottom side, a T-flange on the top side, a first extrusion, and a second extrusion, a first of the at least four cross laminated timber panels including the first extrusion attached to the first side and the second extrusion attached to the top side, a second of the at least four cross laminated timber panels including the first extrusion attached to the second side and the second extrusion attached to the top side, a third of the at least four cross laminated timber panels including the first extrusion attached to the first side and the second extrusion attached to the bottom side, and a fourth of the at least four cross aminated timber panels including the first extrusion attached to the second side and the second extrusion attached to the bottom side;

installing the first of the at least four cross laminated timber panels;

installing the fourth of the at least four cross laminated timber panels on the second of the at least four cross laminated timber panels by connecting the second extrusion of the fourth of the at least four cross laminated timber panels with the second extrusion of the second of the at least four cross laminated timber panels, inserting the T-flange of the second of the at least four cross laminated timber panels into the notch of the fourth of the at least four cross laminated timber panels, and connecting the first extrusion of the fourth of the at least four cross laminated timber panels;

installing a second splice plate in the second extrusion of the first of the at least four cross laminated timber panels prior to installing the third of the at least four cross laminated timber panels.

8. A method of installing a wall system comprising:

installing the first of the at least four cross laminated timber panels;

installing a third splice plate in the second extrusion of the second of the at least four cross laminated timber panels prior to installing the fourth of the at least four cross laminated timber panels.

9. A method of installing a wall system comprising:

installing the first of the at least four cross laminated timber panels;

installing a fourth splice plate in the first extrusion of the third of the at least four cross laminated timber panels prior to installing the fourth of the at least four cross laminated timber panels.