Building Envelope Systems

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/471,486, filed on Jun. 6, 2023.

BACKGROUND OF THE INVENTION

Field of Invention

The present invention relates primarily to a new and improved building envelope systems, and more particularly it relates to the building envelope systems which improve performances of the wall, roof and soffit assemblies including significantly increased speed of assembly.

Description of Related Art

Traditional sheathing materials and weather barriers are not quite efficient to provide good thermal and acoustic performance, and significant weatherproofing of wall assemblies. Hence, there is a significant need and void in the market to invent complete Building Envelope Systems which improves performances of wall, roof and soffit assemblies including significantly increased speed of assembly by replacing traditional sheathing materials and weather barriers with fiber reinforced polymers (FRP's) through elimination of most mechanical fasteners. Because of this the wall assemblies with be lighter weight, have good thermal and acoustic performance, and significantly increased weather-proofing of wall assemblies. In prefabrication, sealing will also be provided between all wall sections. The FRP sheathing will have no weather-barrier penetrations, have greater planarity between pre-fabricated wall sections both in assembly and in installation onto buildings, and will have less risk shipping pre-fabricated wall sections. The Building Envelope Systems will have full adjustability to plane and level walls, and consistency in façade mounting regardless of façade material type. Each of these improvements would be notable advancements in these fields.

The present invention is hereinafter disclosed, which provides weather-proofing and more thermally efficient wall assemblies. The unique characteristics and features of the present invention are, therefore, unrepresented within the conventional wall assemblies. Hence, the present invention has been disclosed to provide solutions to the aforementioned needs, and to resolve the aforementioned deficiencies in the conventional wall assemblies.

SUMMARY OF THE INVENTION

In accordance with the present application, novel and useful Building Envelope Systems is herein provided which includes new products and methods of wall manufacturing including a new sub-girt/sheathing system which eliminates sheathing fasteners and weather barriers. New head and sill tracks will replace traditional framing tracks in prefabrication, and new horizontal and vertical seals will replace, at least in part, much of the flashing materials traditionally used as well as the backer rod and sealant required between wall panels.

Established products and manufacturing processes including Fiber Reinforced Plastics (FRP) will be used to make the new structural sub-framing and sheathing components. FRP will be used to make the new combined sheathing and weather-proofing component. In addition, FRP will be used to make the new combined head/sill tracks and flashing components. Fibers used in the FRP process may vary depending on project requirements to include fibers such as glass, Kevlar, basalt and carbon. Example, for thermal performance glass fibers may be used, but for ballistic and blast performance Kevlar fibers may be used. These products may all be manufactured using a pultrusion process or other acceptable method of manufacture.

These new products' use of FRP provides for extreme thermal efficiency for prefabricated walls (unitized walls) which will translate to lower operating costs for the life of the building. The use of certain adhesives, the use of FRP's, and gaps between the FRP and structural framing are anticipated to help reduce vibration for better acoustic dampening and deadening performance.

Metal supports will be used minimally for occasions when additional pull-out strength is needed such as for fastening cladding to the new FRP framing member. These metal supports may be made of a material such as galvanized steel which may be cut on a shear and bent on a brake press. These components may then be installed into the new framing member by means of sliding or snapping the steel into the FRP which will friction-fit into its final position when fully installed with or without adhesives used for additional holding strength.

The new FRP head and sill tracks as well as the new FRP framing members are made to encompass the new FRP sheathing/weather barrier. This encompassing, along with adhesives used on the full perimeter of the sheathing/weather barrier, will provide a water-proof wall, roof, floor, soffit or other structural building system which is sealed at the outer-most location on the wall panels while insulating between wall panels.

Rubber-like and closed cell foam seals, including solid, hollow and open shapes, will be used as a continuous head track seal to not allow water to gain access between prefabricated wall sections mounted to a building in curtainwall fashion. This material will be made of a material such as extruded rubber silicone or neoprene, or polyethylene foam. The seals will be shaped to partially or fully cover flanges, webs, insulation, and other seals, and may have liquid insulation injected inside hollow openings to better seal and insulate. This seal may be adhered, frictionally fit, and/or be mechanically fastened to other materials to positionally hold in in place until the wall panels are installed which will then permanently hold them in place. The seal may have one or more sides having an incline plane to shed water, to allow for a premium shape when axial, lateral or bend pressures are applied, and will help hold additional adjacently placed insulation in place, such as pinching it between the seal and another surface.

It may be apparent that novel and useful Building Envelope Systems has been hereinabove described which will work and be used in a manner not consistent with conventional products and methods to provide great improvements in many facets of the manufacturing, assembly, installation, and overall performance of complete building envelope systems.

It is therefore an object of this application to provide Building Envelope Systems which are lighter, stronger, easier, and less expensive compared to traditional practices.

It is another object to provide an integrated sub-framing and sheathing system eliminating sheathing, its fasteners, and offsetting most of their associated installation labor.

It is another object to provide an integrated sub-framing and sheathing system which is able to support more shear loads than gypsum products.

It is another object to provide head and sill tracks which incorporate the full or partial shape of commonly used metal flashings. Metal flashings such as those used for window openings and wall enclosures may then be made much smaller and adhesively attached to parts of the head and sill tracks. By attaching these smaller adhesively applied metal flashings to the FRP head and sill tracks, the flashings will be much easier to maintain a straight-looking appearance, whereas traditional flashings tend to bend with the installation of each mechanical fastener because they warp the flashings when torqued down.

It is another object to provide structural members, including FRP sheets, with built-in cavities and ledges which allow sheathing, rubber gaskets, adhesives and fasteners to be inserted into the and onto them, both inside and outside structural FRP including at corners and ends, to provide a means to quickly and easily attach many different materials to each other.

It is an object of this application that all parts and components of the present invention may be manufactured with additional holes, bends, knurling, and punching, as well as the addition of different or multiple adhesives for use in all locations for the purpose of structural, thermal, acoustic, weather-proofing and other improved performances, including the use of mechanical fasteners, built-in anti-rotation mechanisms and other features which don't depart from the spirit of this application.

It is another object to incorporate a new prefabricated wall panel to wall panel installation means when mounting fully assembled wall panels onto building super-structures.

Another object is to provide head and sill tracks which have built-in drainage, where exposed or required, including having built-in slope(s).

Another object is to provide sloped and flat entrances for steel inserts to “snap” into position so that smaller segments may be used instead of full-length, or to simplify the installation process of the steel into the FRP, whether installed with or without adhesives.

Another object is to provide steel angles or other shapes which are snapped into the FRP which allows other sub-framing such as steel angles and Z's to be attached to increase the length of the sub-framing for aesthetic or planarity purposes. These angles and Z's may be attached to one or more locations on the FRP sub-framing and/or sheathing, as well as on different planes and elevations.

Another object of the present invention is for the side-seal FRP's to be routed out in such a way that they are able to partially or fully encompass the ends of the sub-framing and sheathings to provide a completely sealed side or edge of wall panel.

The invention possesses other objects or advantages especially with concerns to particular characteristics and features thereof which will become apparent as the specification continues, including using aspects of these different concepts together.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, exemplary constructions of the invention are shown in the drawings. However, the invention is not limited to the specific structures disclosed herein. The description of a structure referenced by a numeral in a drawing is applicable to the description of that structure shown by that same numeral in any subsequent drawing herein. according to an embodiment of the present invention.

FIG. 1 is an isometric elevation section view of a new structural sub-framing member.

FIG. 2 is an isometric elevation section view of variation of the structural sub-framing member of FIG. 1.

FIG. 3 is an isometric elevation section view of the sub-framing member of FIG. 2 showing steel inserts being “snapped” into place.

FIG. 4 is an isometric elevation section view of the preferred sub-framing embodiment having an alternate screw-boss for side-mounted attachments, such as the side seal FRP's, to be added to it.

FIG. 5 is an isometric elevation section view of a variation of the new structural sub-framing member.

FIG. 6 shows an isometric elevation section view of a head track E for prefabricated walls.

FIG. 7 shows isometric elevation section view of the preferred head track F for prefabricated walls.

FIG. 8 shows an isometric elevation section view of a head track seal G.

FIG. 9 shows an isometric elevation section view of compressible insulation H.

FIG. 10 shows an isometric elevation section view of a compressible insulated rubber-like seal I which may be used between head and sill tracks, and/or at the sides of wall panels.

FIG. 11 shows an isometric elevation section view of a sill track J.

FIG. 12 shows an isometric elevation section view of the sill track J of FIG. 11 from a different angle.

FIG. 13 shows an isometric elevation section view of the preferred sill track K embodiment of the present invention.

FIG. 14 shows an isometric plan section view of the preferred side seal L FRP of the present invention.

FIG. 15 shows an isometric elevation view of the preferred side-mount Insulation Strut M of the present invention.

FIG. 16 shows an isometric elevation section view of the preferred sub-framing member B with the preferred Insulation Strut of FIG. 15 shown with the Insulation Strut installed.

FIG. 17 shows an isometric elevation view of alternate Insulation Struts mounted to the bottom and side of a steel Z-girt.

FIG. 18 shows an isometric elevation view of the complete preferred wall assembly representing all of the individual preferred embodiments (except the Insulation Strut).

For a better understanding of the invention of this application, reference is made to the following detailed description of the preferred embodiments thereof which should be referenced to the prior described drawings.

DETAILED DESCRIPTION OF THE INVENTION

Various aspects of the present application will evolve from the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the prior described drawings.

Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of parts illustrated in the accompanying drawings. The invention is capable of other embodiments, as depicted in different figures as described above and of being practiced or conducted in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.

It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility and non-obviousness.

Use of the phrases and/or terms such as but not limited to “exemplary embodiment,” “an embodiment,” “an alternate embodiment,” “one embodiment,” “another embodiment,” or variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or alternatively in the context of more than one embodiment, or further alternatively in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” or in the form “at least one of A and B” means (A), (B), or (A and B), where A and B are variables indicating a particular object or attribute. When used, this phrase is intended to and is hereby defined as a choice of A or B or both A and B, which is similar to the phrase “and/or”. Where more than two variables are present in such a phrase, this phrase is hereby defined as including only one of the variables, any one of the variables, any combination of any of the variables, and all of the variables, for example, a phrase in the form “at least one of A, B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

It is to be understood that the term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps, etc. are optionally present. For example, an article “comprising” (or “which comprises”) components A, B, and C can consist of (i.e., contain only) components A, B, and C, or can contain not only components A, B, and C but also contain one or more other components.

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

With reference to FIG. 1, sub-framing Member A is comprised of first tip 10 which terminates at return 12, which extends into base 14 creating first slot 16 and having face 18. Base 14 terminates into end 20 having first tip 22. From base 14 extends first finger 24 near the end 20. From base 14 also extends arm 32 which is between the first finger 24 and the first tip 10 and having inside corner 30, all of which extend away from face 18 in the same direction, and second slot 26 is created between the arm 32 and the first finger 24. Under arm 34 is located between the second slot 26 and third slot 38. The third slot 38 is located between under arm 34 and radiused tip 42, radiused tip 42 terminating perpendicularly to second finger 40 which terminates into under arm 34. Beyond the second finger 40 on the arm 32 and still extending away from face 18, arm 32 terminates perpendicularly into leg 44. Leg 44 and the second finger 40 create fourth slot 56. Leg 44 has inside face 48 and outside face 46 and terminates into reduced end 52, the reduced end 52 starting at decline 50 and ending at second tip 54.

FIG. 2 shows embodiment B having the same elements for leg 44 and arm 32 shown in FIG. 1, however base 14 terminates at each end with parallel legs 58 and 62 having tips 60 and 64 respectively on one end, and parallel legs 68 and 20 having tips 72 and 22 respectively on the other end, with each pair of parallel legs facing opposite directions.

FIG. 3 shows embodiment B having clip ‘a’ having first tip 74 sliding into the first slot 16 between face 18 and the first tip 10. Clip ‘a’ having multiple holes 78 in body 76, and second tip 80 on the opposite side as the first tip 74. The second tip 80 is pushed with friction (not shown) along the arm 32 via directional arrow 82 until it snaps into place at inside corner 30. Similarly, clip ‘b’ having first tip 84 sliding into the second slot 26 between under arm 34 and the first finger 24. Clip ‘b’ having body 86 and second tip 88 on the opposite side as the first tip 84. The second tip 88 is pushed with friction (not shown) over radiused tip 42 via directional arrow 90 until it snaps into place against under arm 34 and into the third slot 38. Clip ‘c’ is shown having first tip 92 which extends to body 94, which terminates at return 96, which then terminates at second tip 98 being parallel with the body 94. Clip ‘c’ is pushed via directional arrow 100 until return 96 is forcefully and frictionally fit onto the second tip 54 and the first tip 92 if frictionally fit into the fourth slot 56 so as to not easily be removed.

FIG. 4 shows embodiment C including all of the elements of FIG. 3 except that a screw-boss is used on the inside corner of under arm 34 and leg 44, the screw-boss consisting of ramp 104 creating a first slot 106 between it and the under arm 34. The ramp 104 extends to radius 102 which terminates at end 108. End 108 creates second slot 112 between it and leg 44. Hollow 110 is created inside of the radius 102, the under arm 34 and leg 44 and is circular in shape except at the second slot 112.

FIG. 5 shows embodiment D having all of the elements numbered in FIG. 2, having two mirror image sides rotated 180 degrees from each other, with the mirror image beginning in the middle of arm 32 between base 14 and leg 44, so that there is one embodiment D able to accept sheet FRP from all 4 parallel leg locations, with or without the use of adhesives (not shown) in any of the slots or other locations. The FRP sheets ‘d’ and ‘e’ having base 114 terminating at ramp 117 which terminates into finger 116 having end 119. Cavities 111 and 115 are created which may be filled with insulation or sealed shut with custom routed side seal FRP's (not shown) to trap the air (not shown) and use the air (not shown) as insulation. The structural sub-framing member D allows FRP or other sheets to be added on both sides, whether adhered or not, to provide an exterior façade as well as interior water proofing. The façade may be perforated, specially shaped, and made of any known materials and fabricating methods.

FIG. 6 shows head track E having first tip 118 extending to first vertical finger 120 which terminates at inside bend 122. The inside bend 122 extends first arm 134. The first arm 134 extends perpendicularly to second finger 124 which extends to return 130 which then terminates parallel to second finger 124 at second tip 126, and the second finger 124 located on the opposite side of the first arm 134. The first arm 134 terminates substantially parallel to second arm 136, however at the second arm 136, third finger 146 extends perpendicularly and parallel to second finger 124. Third finger 146 consists of ledge 140 which extends perpendicularly from it and away from second finger 124, then terminating to perpendicular tip 144 which is parallel to third finger 146 and away from the second arm 136. First slot 138 is created between ledge 140 and the second arm 136. Second slot 142 is created between third finger 146 and the perpendicular tip 144. Extending from the second arm 136 away from the third finger 146 are the same elements shown at the same locations as FIG. 3 at leg 44.

FIG. 7 shows preferred head track embodiment F having all of the same elements and locations as shown in FIG. 6, but with all of the elements and locations of inside corner of arm 34 and leg 44 of FIG. 4.

FIG. 8 shows seal G having first end 148 extending vertically to return 152 which then extends parallel to the first end 148 via wall 154 creating slot 150 between them. Wall 154 terminates at first corner 156 which extends perpendicularly to base 158, base 158 terminates perpendicularly at second corner 160 which extends to second end 162.

FIG. 9 shows compressible insulation H having body 168, tapered end 166 and back 164. Front 170 may be exposed to the elements and is intumescent coated or dipped (not shown). The compressible insulation H made up of whether rock mineral wool or polyethylene foam with a black facer, such as a black rock mineral wool fabric or black paint such as intumescent paint which will grow outwards of the building to help prevent a fire from climbing the building, and which may be used between wall panels and above window and other openings on walls and other locations.

FIG. 10 shows preferred seal I have rounded end 172 extending vertically to arm 173 which terminates substantially at first perpendicular rounded corner 176. The first perpendicular rounded corner 176 extends to a sloped top 180 which extends to a second perpendicular rounded corner 174 which then terminates perpendicularly to bottom 178, creating a first cavity 182 which may be filled with insulation ‘g’. The bottom 178 is not required but shown as possible. The bottom 178 extends away from the first rounded corner 176 perpendicularly to incline corner 181. The incline corner 181 extends upwards to a first member 183 which creates a second cavity 185 between it and the second rounded corner 174. The first member 183 extends to return 184 which then extends to a second member 186 which terminates at end 188. The first member 183 and the second member 186 form a slot 187 between them. The slot 187 will fit over the first tip 118 and the first vertical finger 120 of FIG. 6, allowing the preferred seal I to rest on preferred head track F to make a continuous seal across as many premanufactured and installed wall sections (not shown) as possible to eliminate the sealing problem (not shown) of that type of panel intersection (not shown).

FIG. 11 shows sill track J having a first end 190 extending to a sloped drip edge 192 which extends substantially parallel to base 218. Prior to base 218, first finger 194 extends perpendicularly upwards and parallel to second finger 198 which also extends perpendicularly upwards and parallel to the first finger 194 to create a first slot 196. The second finger 198 extends to s-bend 200 which then extends parallel to and above the second finger 198 at an upward member 202 having a second end 204. Base 218 extends to corner 206 at arm 210 which extends perpendicular upwards to first return 216 which extends to third end 212 to create a second slot 214. Base 218 further extends to upright 232 creating third slot 230 between the upright 232 and the arm 210. The upright 232 extends to a second return 224 which extends to downward member 226 to a fourth end 228. A fourth slot 222 is created between the downward member 226 and the upright 232.

FIG. 12 shows sill track J with clips ‘a’ and ‘f’ installed.

FIG. 13 shows preferred sill track K same as the sill track J of FIG. 11, but without the first finger 194 and without the third slot 230. The base 218 instead terminates at a vertical arm 234 which terminates at return 251. In the middle of the arm 234, a leg 240 extends out perpendicularly to terminate perpendicularly to a member 246 which terminates at end 248. At the top of the leg 240, a finger 256 extends upwards and perpendicularly from it creating a slot 250 between the finger 256 and the arm 234.

FIG. 14 shows side seal L having ends 262 at each end facing each other in mirror image, both of which terminate at return 260. Return 260 terminates at base 258 which connects returns 260. Slots 261 are created between ends 262 and base 258. Base 258 may be routed out on back 271 to match sub-framing and sheathing embodiments of this invention to make an air-tight fit and seal (not shown) using adhesives (not shown). Seal LL consists of base 264 extends at an angle to fingers 268 which terminate at ends 270. Fingers 268 may be of different lengths and have rounded or other shaped ends (not shown). Air gaps 272 between fingers 268 may be filled with liquid or other insulation materials (not shown) before or after installation onto a building (not shown). Fingers 268 and ends 270 will contact other surfaces when installed onto a building (not shown), each creating its own independent seal (not shown) on all sides.

FIG. 15 shows an insulation strut M having a first end 276 extending to a first radiused arm 278 which terminates at a first bend 280 which then extends substantially perpendicularly to a first arm 282. The first arm 282 extends to a second bend 284 which extends substantially perpendicularly to a first leg 286. The first leg 286 extends substantially perpendicular to first finger 290 at a third bend 288. The first finger 290 extends to a radiused return 292 which extends to a second finger 296 to create a mounting hole 294 within the radiused return 292. The second finger 296 extends parallel with the first finger 290 and terminates substantially perpendicularly to a second leg 300 at a fourth bend 298. The second leg 300 extends substantially perpendicularly to second arm 304 at fifth bend 302. The second arm 304 extends substantially perpendicular to a second radiused arm 308 at sixth bend 306, with the second radiused arm 308 terminating at a second end 310.

FIG. 16 shows the insulation strut M structurally attached to the sub-framing member B, wherein the insulation strut M, inserted through a hole, rotates perpendicular to the sub-framing member B until lock washers 314 press firmly against the insulation (not shown), at which time a fastener 312 is mechanically fastened through the mounting hole 294 of the insulation strut M and into the sub-framing member B to permanently fix them together.

FIG. 17 shows Z-girt h supporting an assortment of Insulation Struts N, 0, P, Q and R in which their shapes may be seen as well as their connections to any surface orientation or angle.

FIG. 18 shows all of the embodiments and sub-embodiments assembled in a wall assembly, with use of sealants (not shown) in various locations as well as mechanical fasteners.

All aspects of the current invention may be used in conjunction with aspects of other similar inventions that I have been involved with to create hybrid products and systems without departing from the current invention as it should be considered “known”.

The examples and embodiments shown above are intended to be merely exemplary and those skilled in the art shall be able to make numerous variations and modifications to it without departing from the spirit of the present invention. All such variations and modifications are intended to be within the scope of the present invention as defined in the appended claims.