DRY GASKET SYSTEMS AND METHODS OF ASSEMBLING FAÇADE WALL SYSTEMS

Description

TECHNICAL FIELD

This disclosure relates generally to gasket systems for building cladding, and more specifically, to dry gasket systems for building cladding and methods of assembling façade wall systems.

BACKGROUND

Building facades often include non-load bearing building cladding that is supported by the main structure of the building. This cladding may be in the form of a modular wall panel, or a prefabricated wall panel, often made up of a cold form stud wall system, steel and aluminum. These types of modular wall panels are typically attached by a sub-frame to the main structure of the building and include air, water, thermal and vapor control layers, as well as support cladding.

Modular wall panels are pre-assembled before being attached to the building. Modular wall panels need to connect to adjacent panels to inhibit water penetration into the building. Current modular wall panels are typically joined to adjacent wall panels by simple connecting systems that are not waterproof. These simple connecting systems also typically rely on field applied sealants that are not fully reliable long term, and require regular maintenance.

Accordingly, there is a need for improved dry gasket systems and methods of assembling for façade wall systems with dry gasket systems.

SUMMARY

In accordance with a broad aspect, a gasket system for a prefabricated wall panel of a building is described herein. The prefabricated wall panel has a frame panel. The gasket system has a first track configured to be mounted to a first surface of the frame panel. The first track has a base mounted to the first surface of the frame panel, a first rail extending away from the base and a second rail extending away from the base and spaced apart from the first rail by a distance to define a first track cavity. The gasket system also has a second track configured to be mounted to a second surface of the frame panel. The second track has a protruding portion extending away from the second surface of the frame panel. The protruding portion has a height sufficient to enter the first track cavity when the second track engages the first track. The second track also has a first gasket coupled to the protruding portion of the second track. The first gasket is configured to frictionally engage an adjacent first track of an adjacent prefabricated wall of the building.

In at least one embodiment, the first gasket includes an engaging portion, the engaging portion being configured to engage a portion for the second rail.

In at least one embodiment, the portion of the second rail is a side wall of the second rail.

In at least one embodiment, the second rail has a first side wall and a second side wall, the first side wall be fastened to an insulation layer of the wall panel.

In at least one embodiment, the also includes a first sealing member and a second sealing member, the first sealing member being fastened to a first surface of an insulation layer of the wall panel and the second sealing member being fastened to a second surface of the insulation layer of the panel.

In at least one embodiment, the also includes a second gasket coupled to at least one of the first sealing member and the second sealing member.

In at least one embodiment, the first sealing member covers the first surface of the insulation layer.

In at least one embodiment, the second sealing member covers the second surface of the insulation layer.

In at least one embodiment, the second rail has a support member extends between the first side wall and the second side wall and is parallel to the base.

In accordance with another broad aspect, a prefabricated wall panel is described herein. The prefabricated wall panel includes a frame panel and a gasket system. The gasket system has a first track configured to be mounted to a first surface of the frame panel. The first track has a base mounted to the first surface of the frame panel, a first rail extending away from the base and a second rail extending away from the base and spaced apart from the first rail by a distance to define a first track cavity. The gasket system also has a second track configured to be mounted to a second surface of the frame panel. The second track has a protruding portion extending away from the second surface of the frame panel. The protruding portion has a height sufficient to enter the first track cavity when the second track engages the first track. The second track also has a first gasket coupled to the protruding portion of the second track. The first gasket is configured to frictionally engage an adjacent first track of an adjacent prefabricated wall of the building.

In accordance with another broad aspect, a method of installing a façade of a building is described herein. The method includes mounting a first prefabricated wall panel to a structure of the building. The method also includes coupling a second prefabricated wall panel to the first prefabricated wall panel by inserting a portion of a gasket system of the second prefabricated wall panel into a cavity defined by a gasket system of the first prefabricated wall panel. The portion of the gasket system of the second prefabricated wall panel frictionally engages the gasket system of the first prefabricated wall panel.

In accordance with another broad aspect, a method of assembling a prefabricated wall panel of a building is described herein. The method includes coupling a frame panel of the prefabricated wall panel to a cladding panel of the prefabricated wall panel. The method also includes mounting a first track of a gasket system to a bottom surface of the frame panel and a bottom surface of the cladding panel. The first track has a first portion extending downwardly from the underside of the frame panel. The first track also has a second portion extending downwardly from the underside of the frame panel and inwardly spaced from the first portion to form a first track cavity between the first portion and the second portion. The method also includes mounting a second track configured to be mounted to a top surface of the frame panel and to a top surface of the cladding panel. The second track has a protruding portion extending upwardly from the top surface of the frame panel. The protruding portion has a height sufficient to enter the first track cavity when the second track engages the first track. A first gasket is coupled to the protruding portion of the second track and configured to frictionally engage an adjacent first track of an adjacent prefabricated wall panel of the building. A second gasket is coupled to the first track and extends downwardly from the first track below the cladding panel to engage an adjacent second track of another adjacent prefabricated wall panel of the building.

These and other features and advantages of the present application will become apparent from the following detailed description taken together with the accompanying drawings. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the application, are given by way of illustration only, since various changes and modifications within the spirit and scope of the application will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the various embodiments described herein, and to show more clearly how these various embodiments may be carried into effect, reference will be made, by way of example, to the accompanying drawings which show at least one example embodiment, and which are now described. The drawings are not intended to limit the scope of the teachings described herein.

FIG. 1 is a perspective view of a façade wall panel being attached to a building.

FIG. 2 is cross-sectional view of two adjacent façade wall panels and a dry gasket system therebetween according to at least one embodiment described herein.

FIG. 3 is another cross-sectional view of two adjacent façade wall panels and a dry gasket system therebetween according to at least one embodiment described herein.

FIG. 4 is another cross-sectional view of a façade wall panel and a dry gasket system according to at least one embodiment described herein.

FIG. 5 is another cross-sectional view of a façade wall panel and a dry gasket system according to at least one embodiment described herein.

FIG. 6 is an exploded perspective view of a system for attaching a façade wall panel to a building according to at least one embodiment described herein.

FIG. 7 is a cross sectional view of the system for attaching a façade wall panel to a building according to at least one embodiment described herein.

Further aspects and features of the example embodiments described herein will appear from the following description taken together with the accompanying drawings.

DETAILED DESCRIPTION

Various apparatuses, methods and compositions are described below to provide an example of at least one embodiment of the claimed subject matter. No embodiment described below limits any claimed subject matter and any claimed subject matter may cover apparatuses and methods that differ from those described below. The claimed subject matter are not limited to apparatuses, methods and compositions having all of the features of any one apparatus, method or composition described below or to features common to multiple or all of the apparatuses, methods or compositions described below. It is possible that an apparatus, method or composition described below is not an embodiment of any claimed subject matter. Any subject matter that is disclosed in an apparatus, method or composition described herein that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicant(s), inventor(s) and/or owner(s) do not intend to abandon, disclaim, or dedicate to the public any such invention by its disclosure in this document.

Furthermore, it will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the example embodiments described herein. However, it will be understood by those of ordinary skill in the art that the example embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the example embodiments described herein. Also, the description is not to be considered as limiting the scope of the example embodiments described herein.

It should be noted that terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of the modified term, such as 1%, 2%, 5%, or 10%, for example, if this deviation does not negate the meaning of the term it modifies.

Furthermore, the recitation of any numerical ranges by endpoints herein includes all numbers and fractions subsumed within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.90, 4, and 5). It is also to be understood that all numbers and fractions thereof are presumed to be modified by the term “about” which means a variation up to a certain amount of the number to which reference is being made, such as 1%, 2%, 5%, or 10%, for example, if the end result is not significantly changed.

It should also be noted that, as used herein, the wording “and/or” is intended to represent an inclusive—or. That is, “X and/or Y” is intended to mean X, Y or X and Y, for example. As a further example, “X, Y, and/or Z” is intended to mean X or Y or Z or any combination thereof. Also, the expression of A, B and C means various combinations including A; B; C; A and B; A and C; B and C; or A, B and C.

The following description is not intended to limit or define any claimed or as yet unclaimed subject matter. Subject matter that may be claimed may reside in any combination or sub-combination of the elements or process steps disclosed in any part of this document including its claims and figures. Accordingly, it will be appreciated by a person skilled in the art that an apparatus, system or method disclosed in accordance with the teachings herein may embody any one or more of the features contained herein and that the features may be used in any particular combination or sub-combination that is physically feasible and realizable for its intended purpose.

Recently, there has been a growing interest in developing new gasket systems for building cladding, and more specifically, to dry gasket systems for building cladding and methods of assembling façade wall systems.

Turning now to the figures, as noted above, building cladding, or façade walls, are non-load bearing panels that are supported by the main structure of the building. FIG. 1 shows one example of how a façade wall of a building 20 is formed by attaching prefabricated façade panels 10 to the building 20. Façade panels 10 are shown as being hung from a floor slab 22 using adjustable brackets. Façade panels 10 may have outer glazing infill panels, or other design features Examples of how module façade wall panels described herein can be attached to buildings are described in greater detail below.

FIG. 2 shows a cross-sectional view of a gasket system 100 between two adjacent building façade, or cladding, panels 200, according to at least one embodiment described herein. As noted above, façade panel 200 can be applied to the exterior of a building, such as an office building, a residential building, a warehouse or a similar structure.

Façade panels 200 are modular panels that are typically prefabricated off-site and then transported to a building site to be assembled and attached to a building. Façade panels 200 may be particularly well suited to be combined with other façade panels 200 to form an exterior façade wall, or building envelope, of a multiple story structure. As noted in FIG. 1, the façade panels described herein typically have a length in a range of about 20 to 40 feet, or about 25 to 32 feet, and a height in a range of about 8 to 15 feet, or of about 10 to 12 feet.

Façade panels 200, together with gasket system 100, may be used to form a building envelope by, for example, measuring the outer dimensions of the building and determining the size and mounting location of suitably sized façade panels 200. Façade panels 200 can then be preassembled offsite of the building, including a gasket system 100 attached thereto, and brought to the building for mounting thereon. Façade panels 200 with a gasket system 100 are typically mounted vertically adjacent and horizontally adjacent to other façade panels 200 having a gasket system 100, as described below.

Typically, façade panels 200 having a gasket system 100 are not load bearing once they are mounted to a building. Instead, façade panels 200 having a gasket system 100 are attached externally (e.g., outwardly) to load bearing features of the building. For example, façade panels 200 having a gasket system 100 may be mounted to floors, pillars or internal walls of the building. Alternatively, façade panels 200 may be stacked on top of each other without compromising the way the gasket system functions.

Returning now to FIG. 2, shown therein is a magnified view of two adjacent façade panels 200 connected to each other by gasket system 100. Although façade panels 200 are shown as being adjacent to each other vertically, it should be understood that the gasket system 100 may also be used to connect façade panels 200 that are adjacent to each other horizontally. More specifically, FIG. 2 is a cross-sectional view near a top end and a bottom end of two vertically adjacent façade panels 200.

In contrast, FIG. 3 is a horizontal cross-sectional view looking downwardly on two horizontally adjacent façade panels 200. Some of the features of the gasket system 100 shown in FIG. 2 are not shown in FIG. 3 for clarity.

Returning to FIG. 2., each façade panel 200 includes a cladding layer 210, an insulation layer 220 and a frame 230. Optionally, façade panels 200 may also include a sheathing layer 240, as is shown in FIGS. 2 and 4.

Cladding layer 210 is attached to an outer face 222 of insulation layer 220 and insulation layer 220 is attached to an outer face 232 of frame 230. Outer face 212 of each of cladding layer 210 and insulation layer 220 are generally flat. This provides for cladding panel 200 to also be generally flat. Cladding layer 210 also effectively covers insulation layer 220 and insulation layer 220 insulates frame 230, for example from heat passing through from an exterior of the building to the interior.

Cladding layer 210 may be attached to insulation layer 220 by any means known in the art, including but not limited to the fasteners 250 shown in FIGS. 2 and 4. Fasteners 250 may be any screws, bolts or the like suitable for attaching the cladding layer 210 to the insulation layer 220.

In the embodiment shown on FIGS. 2 and 4, additional fasteners 252 may be used to attach a block 254 to the outer face 222 of insulation layer 220 and fasteners 250 may attach the cladding layer 210 to the block 254.

Cladding layer 210 may include almost any material that is suitable for providing protection to the building, including but not limited to ceramic (e.g., porcelain, terracotta or glass fiber reinforced concrete), metal (e.g., aluminum panels) or metal composite materials.

Insulation layer 220 may be a semi-rigid panel or a rigid panel an may include materials such as but not limited to polyurethane (e.g. spray foam polyurethane), fiberglass, mineral wool, polystyrene, phenolic, polyisocyanurate, or any other suitable insulation material. Insulation layer 220 may also be a structured insulated panel or an insulated sandwich panel, for example, where the insulation layer 220 and sheathing layer 240 are coupled and/or form a single, integral layer. Insulation layer 220 may have a thickness in a range of about 50 mm and 300 mm. Insulating material of insulation layer 220 may have suitable fire-ratings so that panel 200 is sufficiently fire retardant to be used as an exterior cladding in accordance with applicable building codes.

Insulation layer 220 may be adhered to the frame 230 by, for example, an adhesive, or a fastener.

Frame 230 typically includes vertical members and horizontal members that are not shown in FIGS. 2 and 4. Frame 230 may be any material suitable for forming an interior wall of a building, such as but not limited to a typical wood stud wall, a hot rolled steel structure, a cold formed steel stud wall, aluminum or similar.

Façade panels 200 are connected to each other using a gasket system 100. Gasket system 100 is configured to provide a water-tight seal between adjacent façade panels 200.

Gasket system 100 includes a first track 102 mounted to a first surface 233 of frame 230. As noted above, although the first track 102 is shown mounted to a bottom surface 233 of frame 230, the first track 102 may be mounted to any surface of frame 230, including a side surface and a top surface.

First track 102 has a base 103 that is attached to frame 130. Base 103 has a generally a flat surface. First track 10 includes two rails, a first rail 104 and a second rail 105 extending away from base 103.

First rail 104 is spaced apart from second rail 105 in a direction towards an interior of the panel 200. First rail 104 being spaced apart from second rail 105 defines a first track cavity 106 therebetween.

First track 104 is generally a hollow track comprising opposing side walls 106, 107 and a wall 108 parallel with and spaced apart from base 103.

Second rail 105 includes spaced apart side walls 109 and 110. Side wall 109 is configured to attach to an interior surface of insulation layer 220 that extends beyond base 103 and the surface of frame 230 that base 103 is attached to. Second track 105 also, optionally, includes a member 111 that provides support to side wall 110.

Gasket system 100 also includes a second track 120 mounted to a second surface 234 of frame 230. As noted above, although the second track 120 is shown mounted to a top surface 234 of frame 230, the second track 120 may be mounted to any surface of frame 230, including a side surface and a top surface.

Second track 120 includes a base 122 that is attached to the second surface 234 of frame 230 and a protruding portion 121 that extends away from base 122. Second track 120 is shown unattached to a frame 230 in FIG. 5.

Protruding portion 121 has a height that is sufficient for the protruding portion 121 to enter the first track cavity 106 when the second track 120 engages the first track 102.

When second track 120 is attached to frame 230, the second track 120 is configured to cover at least a portion of the insulation layer 220 and, optionally, optional sheathing layer 240.

Gasket system 100 also includes a first gasket 130 coupled to the protruding portion 121 of the second track 120.

First gasket 130 is configured to frictionally engage first track 102 of façade panel 200 when façade panel 200 is adjacent to the façade panel 200 having second track 120.

First gasket 130 is coupled to protruding portion 121 and extends in an exterior direction towards an exterior surface of façade panel 200.

For example, first gasket 130 may snap fit to a top and/or exterior surface and/or interior surface of protruding portion 121 and include an engaging portion 132 that extends away from protruding portion 121 and frictionally engages first track 102, such as but not limited to wall 110 of second track 105. Together with protruding portion 121, first gasket 130 provides a water-tight seal and inhibits water from passing from an exterior side of façade panel 200 of an interior side of the façade panel 200 as the protruding portion 121 and the first gasket 130, together, both engage at least side wall 110 of second track 105 and side wall 106 of first track 104.

Each of the end surfaces of insulation layer 220 include a sealing member 223 and 224, respectively. Sealing member 223 is shown being fastened to an underside of insulation layer 220 and sealing member 224 is shown being fastened to a top side of insulation layer 220.

In at least one embodiment, top side of insulation layer 220 and sealing member 224 are configured to slope downwardly in a direction from an interior side of façade panel 200 towards an exterior side of façade panel 200 to inhibit water from travelling from exterior side of façade panel 200 towards interior side of façade panel 200.

Gasket system 100 may also include a second gasket 140 coupled to at least one of sealing member 223 and sealing member 224. In the embodiment shown in FIGS. 2 and 4, second gasket 140 is configured to snap-fit together with sealing member 223 and engage sealing member 224. Second gasket 140 is shown as positioned about between cladding layers 210 of the façade panels 200, however it should be understood that second gasket 140 may be positioned laterally anywhere between the exterior surface of façade panels 100 and first gasket 130.

Sealing members 223 and 224 are generally plastic, or thermally broken aluminum, and may prevent heat transfer from the inside of building to the exterior. Sealing members 223 and 224 may extend along the entirety of the insulation layer 220 or, alternatively, may only extend along a portion of the insulation layer 220.

In at least one embodiment, second gasket 140 prevents about 95% of water that is applied on a building from rain, snow, etc. from entering the interior space between the sealing members 223 and 224.

Also, it should be understood that the second gasket 140 may not be a traditional gasket, it may be any mating component or seal that is configured to fill the space between the sealing members.

Turning now to FIGS. 6 and 7, shown therein is one embodiment of a system 300 for attaching a façade panel 100 to a building 10.

As noted above, façade panels 100 are floating panels that are hung/anchored back to the building slab. The gasket systems 100 described herein lock the façade panels 100 together and maintain air and water tight connectivity between the façade panels 100.

As shown in FIG. 6, a receptor 302 is mounted to structure 12 of building 10. Receptor 302 includes a first member 304 that is fastened directly to the structure 12, as second member 306 that is configured to support a mating piece 310, and a intermediate member 308 positioned between the first member 304 and the second member 306. Second member 306 is configured to support mating piece 310, for example by ledge 307. The first member 304, second member 306 and intermediate member 308 are fastened together by fasteners 311. First member 304 is fastened to the structure 12 by additional fasteners 311.

Mating piece 310 is mounted on frame 230 by fasteners 312. Mating piece 310 includes a first mating piece 313 configured to be fastened to the frame 230 and a second mating piece 314 configured to engage with second member 306. Here, first mating piece 313 is shown as a pair of pieces that engage either side of a vertical support of frame 230. Similarly, second mating piece 314 is shown as a pair of pieces that each are fastened to a respective piece of first mating piece 313.

While the applicant's teachings described herein are in conjunction with various embodiments for illustrative purposes, it is not intended that the applicant's teachings be limited to such embodiments as the embodiments described herein are intended to be examples. On the contrary, the applicant's teachings described and illustrated herein encompass various alternatives, modifications, and equivalents, without departing from the embodiments described herein, the general scope of which is defined in the appended claims.