WO2010065034A2

WO2010065034A2 - Insulated exterior cladding system

Info

Publication number: WO2010065034A2
Application number: PCT/US2008/085493
Authority: WO
Inventors: Ya Peng; Yiqing Yin; Hua Ai; Haidong Hua
Original assignee: Owens Corning Intellectual Capital, Llc
Priority date: 2008-12-04
Filing date: 2008-12-04
Publication date: 2010-06-10
Also published as: WO2010065034A3; CN102282327A

Abstract

An exterior cladding and support system for a wall, includes an insulator attached to the wall, at east one keel mounting bracket secured to the wall and a keel anchored to the wall through the keel mounting bracket. In addition, the system includes at least one panel mounting bracket secured to the keel and a panel anchored to the panel mounting bracket. A method of constructing/refurbishing a wall is also provided.

Description

INSULATED EXTERIOR CLADDING SYSTEM

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE TECHNOLOGY

The present invention relates generally to the fields of building construction and renovation and, more particularly, to an exterior cladding and support system as well as a related method for constructing/renovating a wall.

BAGROUND OF INVENTION

Cast veneer wall panels have been developed as a quick and efficient way to provide a masonry appearance for a building while simplifying construction and lowering construction costs. Such panels typically include a decorative panel carrying a series of design or masonry elements. These design elements simulate brick, stone, tile and other masonry components or materials commonly used in the construction of buildings.

The present invention relates to a wall cladding system that allows for quicker and more efficient installation beyond that currently possible with state of the art cast veneer wall panels. Thus, the system reduces the cost of new construction even further. Many older buildings are also in need of renovation in order to restore the walls of those buildings to desired aesthetic standards. The novel cladding system of the present invention also provides a number of unique advantages that help reduce renovation cost, simplify installation, speed the renovation process and satisfy the customer.

SUMMARY OF THE INVENTION

In accordance with the purposes of the present invention as described herein, an exterior cladding and support system (ECSS) is provided for refurbishing or renovating a wall. The ECSS comprises an insulator attached to the wall, at least one keel mounting bracket secured to the wall, a keel anchored to the keel mounting bracket, at least one panel mounting bracket secured to the keel and a panel anchored to the panel mounting bracket.

More specifically describing the invention, the panel includes at least one embedded anchor sleeve. Each anchor sleeve comprises a body including a threaded bore. In one possible embodiment, the panel includes two reinforced corners with at least one anchor sleeve provided in each reinforced corner.

The keel may comprise an elongated angle iron. The keel mounting bracket may comprise an angle iron segment having a first leg abutting the wall and a second leg projecting from the wall through an opening in the insulator into an air gap formed between the insulator and the panel. The first leg includes at least two slots. First and second fasteners are provided in these slots to secure the keel mounting bracket to the wall. The two slots are elongated to allow for adjustability of the system in a first direction. The panel mounting bracket includes at least two apertures. Third and fourth fasteners are provided in the two apertures to secure the panel mounting brackets to the keel. The two apertures are elongated to allow for system adjustability in a second direction substantially perpendicular to the first direction.

In addition, the ECSS includes at least one panel hanging bracket secured to the panel. The panel hanging bracket includes a channel for engaging the panel mounting bracket secured to the keel. At least one adjustment element is provided in the panel hanging bracket to allow for adjustability of the system in a third direction substantially perpendicular to the first and second directions.

The system is adapted to be versatile and may be used in different modes for different application requirements. In one possible use, the keel extends in a horizontal plane. In another possible use the keel extends in a vertical plane.

In accordance with yet another aspect of the present invention, a method is provided for refurbishing a wall. The method comprises the steps of: (a) attaching an insulator to the wall; (b) connecting a keel mounting bracket to the wall; connecting a keel to the keel mounting bracket; (d) providing a panel mounting bracket on the keel; and

(e) anchoring a panel to the panel mounting bracket. In addition, the method includes providing adjustability for installing the panel on the wall in one, two and/or three different planes or directions all perpendicular to each other. In addition, the method includes providing a hole in the insulator to receive the keel mounting bracket. Further, the method provides for filling that hole with an insulation material after anchoring the keel mounting bracket to the wall.

In the following description there is shown and described multiple embodiments of this invention, simply by way of illustration of some of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments, and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present invention, and together with the description serve to explain certain principles of the invention. In the drawings: Figure 1 is a vertical cross section of the ECSS of the present invention in a first mode of use with the keel extending vertically along the wall;

Figure 2 is a transverse cross section of the ECSS illustrated in Figure 1;

Figures 3A and 3B are a detailed perspective views illustrating the connection between the panel mounting bracket, the panel hanging bracket and the fine adjustment element;

Figure 4 is a vertical cross section of one possible embodiment of the ECSS of the present invention in a second mode of use with the keel extending horizontally across the wall;

Figure 5 is a transverse cross section of another possible embodiment of the ECSS; Figure 6 is a front elevational of the decorative face of the panel; and

Figure 7 is a rear elevational view of the panel.

Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to Figures 1-3 illustrating the exterior cladding and support system or ECSS 10 of the present invention. Advantageously, the ECSS 10 is useful for both new construction and to renovate or refurbish an existing wall W. The wall W may be made from substantially any known building material including but not limited to wood sheeting, concrete, brick and stone. The ECSS 10 includes an insulator 12 that may be formed from a sheet of rigid foam insulation such as sold by Owens Corning under the FOMULAR trademark. Of course, it should be appreciated that substantially any other foam insulating product useful for the intended purpose may be used.

At least one keel mounting bracket 14 is secured to the wall. Each keel mounting bracket 14 may take the form of an angle iron segment. As best illustrated in Figures 2 and 3, each keel mounting bracket 14 includes a first leg 16 abutting the wall W and a second leg 18 projecting through an opening 20 in the insulator 12 into an air gap G formed between the insulator and the cladding panel 22.

As best illustrated, each keel mounting bracket 14 is mounted to the wall W by at least one first fastener 24. These fasteners 24 may take the form of anchor bolts or any other fastener appropriate for the intended purpose. As illustrated, each fastener 24 extends through a slot 26 provided in the first leg 16 of the keel mounting bracket 14. Since each slot 26 is elongated, the keel mounting bracket 14 may be shifted to the left or right in Figure 2 and thus system adjustment is provided in a first plane or direction.

A keel 28 is anchored to the wall W by means of the keel mounting brackets 14. The keel 28 may take the form of an elongated angle iron or rectangular iron formed from metal (for example, aluminum or steel), fiber reinforced plastic or other appropriate material. Cooperating bolts and nuts or other fasteners 30 may be used to secure the keel 28 to each of the aligned keel mounting brackets 14 (two brackets 14 are illustrated in Figure 1). A series of panel mounting brackets 32 are provided at spaced locations along the keel 28. Each panel mounting bracket 32 comprises an angle iron segment. Each panel mounting bracket 32 includes a base leg that has two elongated apertures 34. Each panel mounting bracket 32 is secured to the keel 28 by two or more fasteners 35 such as bolts or screws. The elongated apertures 34 allow the bracket 32 to be shifted with respect to the keel 28 in a second plane or direction toward or away from the wall W. Thus, the second direction is perpendicular to the first direction. After making the desired adjustment, the fasteners 34 are tightened to securely hold the bracket 32 in position on the keel 28.

The panel 22 is anchored onto the panel mounting brackets 32 by means of spaced panel hanging brackets 36. The panel 22 may be made from glass fiber reinforced concrete (GRC) or other appropriate material. Where GRC is used, it could be formulated with a cement and fine aggregate mix containing about five percent of glass fiber strands. The panel 22 may be formed by molding, machining or other process in a manner known in the art. As illustrated in Figure 6, the panel 22 may include a decorative face 38 to mimic natural stone, brick, finished stone or substantially any other appropriate building material. The pattern of design elements may be varied as desired in order to produce any number of aesthetically pleasing cladding products.

As best illustrated in Figure 7, the rear of the panel 22 may include reinforced corners 40 and a weight saving cavity 42 in the middle. One or more anchor sleeves 44 are embedded in each reinforced corner 40 of the panel. Each anchor sleeve 44 comprises a body 46 including a threaded, blind bore 48 that is open at the rear of the panel 22. As shown, annular reinforcements 52 at the ends of the body 46 protect the sleeve from damage. These reinforcements 52 also prevent the sleeves from pulling out of the GRC material that forms the panel 22.

A panel hanging bracket 36 is mounted to the panel 22 at each anchor sleeve 44 by means of one or more bolts or other appropriate fasteners 54. Each bracket 36 includes a channel 56. The channel 56 is used to mount the panel 22 onto the panel mounting brackets 32. More specifically, as best illustrated in Figures 1 and 3, the channel 56 is positioned over the projecting lug 58 of a panel hanging bracket 36 so that the end of the lug engages the bottom of the channel. An adjustment element 60, in the form of bolts, extends through the bracket 36 at the bottom of the channel. By turning the bolts 60 clockwise or counterclockwise, the panel may be shifted up or down in Figure 1 and in or out of the page in Figure 2. Thus, fine adjustment in a third plane or direction is provided. Significantly, this third direction of adjustment is perpendicular to both the first and second directions. By allowing for adjustment of the positioning of the panel 22 on the wall W in the X, Y and Z directions, it should be appreciated that a panel can be precisely positioned on a wall as required to provide the most aesthetically pleasing installation possible. Adjacent panels may be easily aligned and gaps between panels may be conveniently eliminated. Thus, the ECSS 10 is a user friendly product.

Figures 4 and 5 illustrate a second mode of using the ECSS 10 to construct a new wall W or to refurbish or renovate an old wall W. As illustrated, the various components of the ECSS 10 are identified by the same reference numbers used in the above description. Thus, the insulator is reference number 12, the keel mounting bracket is reference number 14 and so on. As shown in Figures 4 and 5, the keel mounting brackets 14 and keels 28 have be reoriented through 90 degrees. Thus, the keels 28 now extend horizontally across the wall W rather than vertically as illustrated in figures 1 and 2. In the embodiment illustrated in Figure 4, the panel hanging brackets 36 are connected directly to the keel 28 with the channel 56 receiving and holding the upwardly projecting leg of the keel. In this embodiment, the panel hanging bracket 36 functions as the panel mounting bracket 32 allowing the panel 22 to be secured directly to the keel 28. In the embodiment illustrated in Figure 5, the panel hanging brackets 36 are connected to the panel mounting brackets 32 mounted to the keel 28.

Advantageously, the ECSS 10 is adapted for use in either mode or orientation. Thus, the ECSS 10 is a versatile and flexible system that may be used as desired to meet the needs of any particular application. As should be appreciated, in either mode of use, the steps of the installation are completed in the same order and the panel 22 is hung on the wall W by simply hooking the channels 56 of the panel hanging brackets 36 on the lugs 58 of the panel mounting brackets 32 carried on the keels 28. Adjustment in the X, Y and Z directions is possible in either mode so that proper fit and finish between adjacent panels 22 is insured in a simple and efficient manner. The method of installation of the ECSS 10 will now be described in detail. First, the wall W is prepared as necessary for the installation. Thus, any necessary cleaning, repair, removal work or the like that must be done to the wall W is completed. Next, the insulator 12 is attached to the wall W. Typically the insulator 12 is attached by a series of fasteners (not illustrated) such as concrete screws or the like as appropriate for fastening to the composition of the wall W. The keel mounting brackets 14 are then connected to the wall W at the appropriate positions to hold the keels 28. More specifically, holes or openings 20 are provided or cut in the insulator 12 at the appropriate mounting points (alternatively, these could be precut into the insulators at the place of manufacture). The keel mounting brackets 14 are then secured to the wall with appropriate fasteners such as anchor bolts 24. The holes or openings 20 may then be filled with an insulation material if desired.

Next, the keel 28 is connected to the wall W by means of the keel mounting brackets 14. More specifically, the keel 28 is positioned in between the keel brackets 14 and bolts 30 are used to secure the keel 28 in position. The elongated slots 24 allow for adjustment horizontally across the wall W in the mode illustrated in Figures 1 and 2 and vertically over the wall in the mode illustrated in Figures 4 and 5. The panel mounting brackets 32 are then connected to the keel 28. This is done at the appropriately spaced points by using the fasteners 35. The elongated apertures in the brackets 32 allow for adjustment in the second plane or direction perpendicular to the first direction: that is, toward or away from the wall W.

The panel 22 is then mounted on the panel mounting brackets 32. This is done by connecting the panel hanging brackets 36 onto the panel 22 using the fasteners 54. The panel 22 is then manipulated so that the channels 56 in the brackets 36 are positioned over and receive the lugs 58 on the brackets 32. The panel 22 may be properly positioned and aligned with an adjacent panel by turning the adjustment element, illustrated as bolts 60, which allows for fine adjustment in a third plane or direction perpendicular to the first direction and the second direction. The resulting gap G between the insulator 12 and the panel 22 forms an air space that allows the wall W to breath so as to control moisture behind the panel 22.

In summary, numerous benefits result from employing the concepts of the present invention. The light weight panels 22 may be installed without the need for heavy crane capacity. They are ideal for use in limited access situations. They may be easily adjusted into proper position in a quick and efficient manner thereby speeding the construction process. Further, they provide the durability and quality finish of reconstructed stone.

The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiment do not and are not intended to limit the ordinary meaning of the claims and their fair and broad interpretation in any way.

Claims

CLAIMS:

1. An exterior cladding and support system for a wall, comprising: an insulator (12) attached to the wall; at least one keel mounting bracket (14) secured to the wall; a keel (28) anchored to said at least one keel mounting bracket; at least one panel mounting bracket (32) secured to said keel; and a panel anchored to said at least one panel mounting bracket.

2. The system of claim 1, wherein said panel includes at least one embedded anchor sleeve (44).

3. The system of claim 2, wherein said at least one embedded anchor sleeve comprises a body (46) including a threaded bore (48).

4. The system of claim 3, wherein said panel includes at least two reinforced corners (40) and at least one anchor sleeve provided in each of said at least two reinforced corners.

5. The system of claim 1, wherein said keel comprises an elongated angle iron.

6. The system of claim 1, wherein said at least one keel mounting bracket comprises an angle iron segment having a first leg (26) abutting said wall and a second leg (18) projecting from the wall through an opening (20) in said insulator into an air gap (G) formed between said insulator and said panel.

7. The system of claim 6, wherein said first leg includes at least one slot (26) and first fastener (24) is provided in said at least one slots to secure said keel mounting bracket to said wall.

8. The system of claim 7, wherein said at least one slot is elongated to allow adjustability in a first direction.

9. The system of claim 8, wherein said at least one panel mounting bracket includes at least two apertures and second and third fasteners are provided in said at least two apertures to secure said at least one panel mounting bracket to said keel.

10. The system of claim 9, wherein said at least two apertures are elongated (34) to allow adjustability in a second direction substantially perpendicular to said first direction.

11. The system of claim 10, including at least one panel hanging bracket secured to said panel, said at least one panel hanging bracket including a channel (56) for engaging said at least one panel mounting bracket on said keel.

12. The system of claim 11, including at least one adjustment element in said at least one panel hanging bracket (36) to allow for adjustability in a third direction substantially perpendicular to said first direction and said second direction.

13. The system of claim 12, wherein said keel extends in a horizontal plane.

14. The system of claim 12, wherein said keel extends in a vertical plane.

15. A method of refurbishing a wall, comprising: attaching an insulator (12) to said wall; connecting a keel mounting bracket (14) to said wall; connecting a keel (28) to said keel mounting bracket; providing a panel mounting bracket (32) to said keel; and anchoring a panel to said panel mounting bracket.

16. The method of claim 15, including providing adjustability of said keel mounting bracket in a first direction.

17. The method of claim 16, including providing adjustability of said panel mounting bracket in a second direction substantially perpendicular to said first direction.

18. The method of claim 17, including providing adjustability of said panel in a third direction substantially perpendicular to said first direction and said second direction.

19. The method of claim 15, including providing a hole (20) in said insulator to receive said keel mounting bracket.

20. The method of claim 19, including filling said hole with insulation material after anchoring said keel mounting bracket to said wall.