US3777430A - Complementary mating elements for double-skin foam core panel - Google Patents

Abstract

A double-skin building construction panel having a foam core and having an outer facing sheet laterally offset from and spaced apart from an inner facing sheet. Each panel presents an overlapping edge portion along one side and an overlapped edge portion along its opposite side. The panels are adapted to be assembled in lapped relation without externally visible fasteners. Mating elements in the outer facing sheets provide a positive mechanical connection of adjacent outer facing sheets and provide for lateral adjustment in the position each panel relative to the previously erected panel. The arrangement is such that during erection, the panels may be gathered or spread apart to conform the coverage provided by all of the panels with that required by the structural framework.

Description

[ Dec. 11, 1973 United States Patent 1 Tischuk COMPLEMENTARY MATING ELEMENTS FOR DOUBLE-SKIN FOAM CORE PANEL Primary Examiner-Price C. Faw, Jr.

Attorney-Harry B. Keck et al.

[75] Inventor: Walter Tischuk, Richmond, Ind.

H. H. Robertson Company, Pittsburgh, Pa.

[57] ABSTRACT A double-skin building construction panel having a [73] Assignee:

[22] Filed. Aug. 30, 1972 foam core and having an outer facing sheet laterally offset from and spaced apart from an inner facing PP N04 285,060 sheet. Each panel presents an overlapping edge portion along one side and an overlapped edge portion along its opposite side. The panels are adapted to be [52] US. 52/309, 52/483, 52/595 [51] Int.

assembled in lapped relation without externally visible E04c 1/10,E04c 2/20 fasteners. Mating elements in the outer facing sheets [58] Field of Search...................... 52/235, 309, 595,

provide a positive mechanical connection of adjacent outer facing sheets and provide for lateral adjustment in the position each panel relative to the previously [56] References Cited UNITED STATES PATENTS erected panel. The arrangement is such that during erection, the panels may be gathered or spread apart to conform the coverage provided by all of the panels Glards 52695 with that required by the structural framework. Tischuk 52/595 6 Claims, 11 Drawing Figures 5040 47.48 r y r 0257 9736 3333 PATENTED BEE 1 I 1975SHEEF 2 OF 3 FIG FIG.7

PATENIED DEC 1 I 1973 SHEET 3 BF 3 COMPLEMENTARY MATING ELEMENTS FOR DOUBLE-SKIN FOAM CORE PANEL BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to double-skin foam core building construction panels of the type erected without externally visible fasteners, and more particularly to improvements in complementary mating elements formed in at least the outer facing sheets of such building construction panels.

2. Description of the Prior Art Double-skin building construction panels having no lateral adjustment capability and which are erected without externally visible fasteners are known in the prior art for use in the construction of buildings, see U.S. Pat. Nos. 3,290,845 (SNYDER, Dec. 13, 1966), 3,535,844 (GLAROS, Oct. 27, 1970); 3,667,180 (TIS- CHUK, June 6, 1972). Double-skin building construction panels having some lateral adjustment capability and which are erected without externally visible fasteners also are known in the prior art, see U.S. Pat. No. 3,372,520 (HENSEL, Mar. 12, 1968).

The SNYDER, GLAROS and TISCHUK panels require extensive field cutting and fitting to conform the lateral coverage of the panels with that dictated by the structural-framework. The HENSEL arrangement requires the use of specially shaped, slotted and apertured subgirts in combination with a special clamping plate and fastener to achieve erection and lateral adjustment of the panels. Moreover, the erection and lateral adjustment require the cooperative effort of workmen positioned exteriorly and interiorly of the building framework.

SUMMARY OF THE INVENTION The principal object of this invention is to provide an improved laterally adjustable weather-tight joint between double-skin foam core building construction panels.

Another object of this invention is to provide improved complementary mating elements for at least the outer facing sheet of a double-skin foam core building construction panel, which mating elements permit the panels to be gathered or spread apart thereby to conform the lateral coverage of the panels with that required by the structural framework.

Still another object of this invention is to provide improved complementary mating elements which permit lateral adjustment of the position of each panel relative to a previously erected panel without impairing the weather seal.

The present invention provides improvements in the building construction panel described and illustrated in U.S. Pat. No. 3,667,l80, supra. In the building construction panel of U.S. Pat. No. 3,667,180, supra, each of the facing sheets includes a central web, first and second side walls extending along the opposite side edges of the central web and a flange extending outwardly from the second side wall generally parallel to the central web. The facing sheets are assembled such that the flange of each facing sheet confronts the opposing central web of the other facing sheet and is laterally spaced-apart from the first side wall of the other facing sheet.

In accordance with the present invention, connecting means formed in the first and second side walls of the outer facing sheet provide a positive mechanical connection between the outer facing sheets of adjacent panels. The connecting means, in the form of a recess and a complementary tongue, are arranged such that the position of each panel relative to the previously erected panel may be adjusted laterally, whereby the lateral coverage provided by all of the panels is conformed with that required by the lateral dimensions of the building structural framework.

The recess is formed integrally with the second side wall of the outer facing sheet and is spaced-apart from both the central web and the flange. The recess, having a generally U-shaped configuration, presents confronting first and second interior wall segments extending generally parallel with the central web, and a connecting wall segment. The complementary tongue is formed integrally with the first side wall of the outer facing sheet and extends outwardly therefrom into the recess of the adjacent facing sheet. The complementary tongue comprises a first exterior wall segment which is generally parallel with the first interior wall segment of the recess. A second exterior wall segment adjoins the first exterior wall segment to provide a leading edge remote from the first side wall. Preferably, the second exterior wall segment of the tongue forms an acute angle with the first exterior wall segment. A sealant in the fOlIl'l of a bead of caulking material or a sealant strip formed from a soft, closed cell plastic or sponge rubber, is introduced into the recess at a location wherein the sealant is penetrated by the leading edge of the adjacent facing sheet to provide a weather-tight seal.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary elevation view of the present building wall panels erected on a building structural framework;

FIG. 2 is a cross-sectional view taken along theline 22 of FIG. 1, illustrating the transverse profile of the present building construction panel;

FIG. 3 is an exploded, isometric view of clip and fastener means;

FIG. 4 is a fragmentary cross-sectional view taken along the line 4-4 of FIG. 1;

FIG. 5 is an end view illustrating the profile of the facing sheets used in the building panel of FIG. 2;

FIG. 6 is a fragmentary cross-sectional view, taken along the line 6--6 of FIG. 1, illustrating the normal joint spacing between adjacent panels;

FIGS. 7 and 8 are fragmentary cross-sectional views, similar to FIG. 6, illustrating the minimum and maximum joint spacing between adjacent building panels;

FIG. 9 is a fragmentary cross-sectional view taken along the line 99 of FIG. 1;

FIG. 10 is an isometric view illustrating an alternative sealant strip; and

FIG. 11 is a fragmentary cross-sectional view similar to the right hand half of FIG. 6, illustrating the sealant strip of FIG. 10 installed in the present panel.

DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 illustrates a buildingstructural framework 10 of which only vertically spaced horizontal sub-girts 11 and two laterally spacedvertical columns 12a, 12b are illustrated. The buildingstructural framework 10 supports awall structure 13. Thewall structure 13 is assembled fromplural building panels 14 erected in edge overlapped relation and presentingplural joints 15. Each of thepanels 14 is secured to selected ones of the subgirts 11 by clip and fastener means 16.

Each of the panels 14 (FIG. 2) comprises an outer facingsheet 17, an inner facingsheet 18 and aplastic foam core 19 disposed between the facingsheets 17, 18. Each of the facingsheets 17, 18 includes acentral web 20 having first andsecond side walls 21, 22 provided along the opposite longitudinal edges thereof. Aflange 23 extends outwardly from the second side wall and is generally parallel with thecentral web 20.

The facingsheets 17, 18 are laterally offset from one another, overall arrangement being such that theflange 23 of each facing sheet 17(18) confronts the opposingcentral web 20 of the other facing sheet 18(17) and is laterally spaced-apart from thefirst side wall 21 of the other facing sheet 18(17). Thepanel 14 presents an overlappingedge portion 24 and an overlappededge portion 25. Agap 26 is presented at each of theedge portions 24, 25 between theflange 23 and the adjacentfirst side wall 21. Thefoam core 19 is exposed at thegaps 26.

The fastening means 16 (FIG. 3) comprises aclip member 27 and afastener 28. Theclip member 27 includes afirst arm 29 provided with central and endapertures 30 and asecond arm 31. Theclip member 27 preferably is in the form of an angle wherein the first andsecond arms 29, 31 are mutually perpendicular. Thefastener 28 preferably is of the self-tapping type.

When theclip 17 is installed (FIGS. 4 and thefirst arm 29 overlies theflange 23 of the outer facingsheet 17 and thesecond arm 31 extends into thefoam core 19 in the region (gap 28) between theflange 32 of the outer facingsheet 17 and thefirst side wall 21 of the inner facingsheet 18. Thefastener 28, when installed, extends through one of theopenings 30 in thefirst arm 29, thefoam core 19, the inner facingsheet 18 into the sub-girt 11. It will be appreciated that theclip member 17 and thefastener 28 cooperate to provide a positive connection between the outer facingsheet 17 and the inner facingsheet 18, and to positively secure the inner facingsheet 18 to the sub-girt 11. For a more complete description of the fastening means 16, reference is made to U.S. Pat. No. 3,667,180, supra.

Referring to FIG. 5, each of the facing sheets 17 (18) presents arecess 32 and acomplementary tongue 33. Therecess 32 is formed in thesecond side wall 22 and is spaced-apart from both the central web and theflange 23. Therecess 32 has a generally U-shaped configuration including confronting first and secondinterior wall segments 34, 35 which extend generally parallel with thecentral web 20, and a connectingwall segment 36.

Thecomplementary tongue 33 is formed in thefirst side wall 21 and comprises first and secondexterior wall segments 37, 38. The firstexterior wall segment 37 adjoins thefirst side wall 21 and extends outwardly therefrom generally parallel with thecentral web 20. The secondexterior wall segment 38 adjoins the firstexterior wall segment 37 to provide aleading edge 39 remote from thefirst wall segment 21. The secondexterior wall segment 38 extends away from thecentral web 20 and forms an acute angle indicated at 40, with the firstexterior wall segment 37.

It will be observed in FIG. 5 that therecess 32 has an interior height indicated at 41 and that thetongue 33 has an exterior thickness indicated at 42. Also, the hiddenface 45 of the firstexterior wall segment 34 of therecess 32 is spaced from theexterior web face 47 at a distance indicated at 43; and that the exposedface 46 of the firstexterior wall segment 37 of thetongue 33 is spaced from theexterior web face 47 at a distance indicated at 44. In accordance with the present invention and depending upon the gauge of metal used in forming the facingsheet 17, 18, theinterior height 41 of therecess 32 exceeds thethickness 42 of thetongue 33 by 2 to 4 metal thicknesses; and thedistance 44 exceeds thedistance 43 by l to 2 metal thicknesses. The overall arrangement is such that whenadjacent panels 14A, 14B (FIG. 6) are assembled to form the joint 15, thetongue 33 of thepanel 14B is centered with respect to therecess 32 of theadjacent panel 14A. Note also that the exposedtongue face 46 is spaced apart from the hiddenrecess face 45.

Further in accordance with this invention, abead 56 of sealant material (FIG. 5) is applied across substantially the entire width and along the entire length of the hiddenface 45 of therecess 32.

FIG. 6 illustrates the normal installed position of theadjacent panels 14A, 14B. It will be observed that aspace 50 normal joint spacing is presented at the joint 15. However, thedimensions 48 and 49 (FIG. 5) are such that the normaljoint spacing 50 can be adjusted between two extremes, that is, wherein no space minimum joint spacing 55 (FIG. 8) is presented at the joint 15; and wherein a maximum joint spacing 51 (FIG. 7) is presented at the joint 15. Thus in accordance with this invention, the position of each panel may be adjusted laterally with respect to that of the previously erected panel prior to securing each panel to the subgirts 11. For example, in the joint formed between panels of one commercial embodiment, the normal joint spacing is three-thirtysecondth inch; the maximum permissible joint spacing is three-sixteenth inch; and the permissible variation in the joint space from three-thirtysecondth inch is plus or minus threethirtysecondth inch.

It will also be appreciated that since the fastening means 16 (FIG. 6) is installed from the exterior of the building framework, the entire wall structure 13 (FIG. 1) can be erected by workmen positioned solely at the exterior of the building framework.

The importance of the position and extent of the sealant bead 56 (FIG. 5) within therecess 32 will now become apparent from the following. A fragment of apanel 14C is illustrated in dotted outline at the right hand side of FIG. 6. It will be observed that as thetongue 33 of thepanel 14C enters therecess 32 of the previously erected panel 148, the leadingedge 39 is positioned to engage thesealant bead 56. When thetongue 33 reaches its final position, as shown at the left hand side of FIG. 6, a portion of thesealant head 56 has been displaced from its initial position. However, since the exposedtongue face 46 is spaced-apart from the hiddenrecess face 45, a portion of thesealant head 56 remains between the exposedtongue face 46 and thehidden recess face 45. The same is true for the panels at the maximum joint spacing 51 (FIG. 7) and for the minimum joint spacing 55 (FIG. 8). Accordingly, regardless of the joint spacing, a weather-tight seal is provided.

Returning to FIG. 1, it will be observed that corner panels 14a, 14b are applied to thevertical columns 12a, 12b. The construction and installed position of a typical corner panel is illustrated in FIG. 9. The corner panel 14a (14b) has no exposed trim elements and provides an aesthetically pleasing, visual continuity in the appearance of the panels along adjacent building faces. The panel 14a may comprise one of thepanels 14 which is bent along its longitudinal center line of the facingsheet 17.

Referring again to FIG. 1, each of thepanels 14 has a modular width indicated at M, which corresponds to the distance between the first andsecond side walls 21, 22 (FIG. 5). Prior to erecting thepanels 14, the overall distance indicated at D in FIG. 1, between the corner panels 14a and 14b is determined. If the position of thevertical columns 12a, 12b is in accordance with the engineering drawings, then thepanels 14 can be erected at the normal joint spacing 50 (FIG. 6). However, if the distance between thevertical columns 12a, 12b is ei ther less than or greater than that specified, the difference will be reflected in the overall distance D.

The joint spacing is determined by subtracting from the overall distance D, the product of the number of panels times the modular coverage M. The remainder is then divided by the number ofjoints. Erection of thepanels 14 to the desired joint spacing may be accomplished by the aid ofgauges 52 of which only one is illustrated in FIGS. 6 and 7. Thegauge 52 has a gaugingend 53 adapted to be inserted between the adjacent panels 14a, 14b and ahandle 54. The gaugingend 53 may, for example, be provided with one ormore strips 55 of predetermined thickness to arrive at the desired joint spacing.

FIG. illustrates analternative sealant strip 57 formed from soft polyvinyl chloride or soft silicone rubber preferably of the closed cell type. One face of thesealant strip 57 is provided with anadhesive coating 58 which is protected by astripable backing sheet 59. Thesealant strip 57 is installed in therecess 32 of thepanel 14D (FIG. 11). When installed, thesealant strip 57 is secured by the adhesive coating 58 (FIG. 10) to the connectingwall segment 36. Thesealant strip 57 also engages theinterior face 45 of the firstinterior wall segment 34 and is thus positioned for engagement by thetongue 33 of theadjacent panel 14E thereby to provide a weather-tight seal.

I claim:

1. In a wall structure assembled from plural building panels spanning across plural spaced-apart sub-girts of a structural framework and erected in side-by-side overlapped relation; each of said panels having an outer facing sheet laterally offset from and spacedapart from an inner facing sheet, and a foam core disposed therebetween; each of said facing sheets including a central web, first and second side walls extending along the opposite sides of said central web, and a flange extending outwardly from the second side wallgenerally parallel to said central web, the flange of each facing sheet confronting the opposing central web of the other facing sheet and being laterally spaced-apart from the first side wall of the other facing sheet; said panels being erected (a) with the first side wall of each facing sheet confronting the second side wall of the adjacent facing sheet, and (b) with said flange of each outer facing sheet positioned inboard of and spacedapart from said flange of each said inner facing sheet; and clip and fastener means engageable with the flanges of the outer facing sheets for securing said panels to certain of said sub-girts; the improvement in laterally adjustable connecting means providing a positive mechanical connection between the outer facing sheets of adjacent panels, comprising:

said second side wall of each outer facing sheet having a recess formed integrally therein and sacedapart from said central web and from said flange. said recess comprising confronting first and second interior wall segments extending generally parallel with said central web, and a connecting wall segment; and a complementary tongue formed integrally with said first side wall of each outer facing sheet and extending outwardly therefrom into the recess of the adjacent facing sheet, said complementary tongue comprising a first exterior wall segment confronting said first interior wall segment and being generally parallel therewith, and a second exterior wall segment adjoining said first exterior wall segment to provide a leading edge remote from said first side wall; the width of said complementary tongue and the depth of said recess being such that prior to securing said panels to said subgirts, the position of each panel may be adjusted laterally with respect to the previously erected panel, thereby to conform the lateral coverage provided by all of said panels with that required by said structural framework. 2. The improvement of claim 1 including a sealant material applied to the first interior wall segment of said recess, said sealant material being penetrated by said leading edge of the adjacent facing sheet to provide a weathertight seal. 3. The improvement ofclaim 2 wherein said second exterior wall segment forms an acute angle with said first exterior wall segment. 4. The improvement ofclaim 2 wherein the first interior wall segment of said recess is positioned adjacent to said central web. 5. The improvement of claim 1 wherein the spacing between the first and second side walls of form throughout said wall structure.

6. The improvement of claim 1 wherein said second and first side walls of each said inner facing sheet are provided with a said recess and a said complementary tongue, whereby laterally adjustable positive mechanical connections also are provided between the inner facing sheets of adjacent panels.

the outer facing sheets of adjacent panels is uni-

Claims (6)

1. In a wall structure assembled from plural building panels spanning across plural spaced-apart sub-girts of a structural framework and erected in side-by-side overlapped relation; each of said panels having an outer facing sheet laterally offset from and spaced-apart from an inner facing sheet, and a foam core disposed therebetween; each of said facing sheets including a central web, first and second side walls extending along the opposite sides of said central web, and a flange extending outwardly from the second side wall generally parallel to said central web, the flange of each facing sheet confronting the opposing central web of the other facing sheet and being laterally spaced-apart from the first side wall of the other facing sheet; said panels being erected (a) with the first side wall of each facing sheet confronting the second side wall of the adjacent facing sheet, and (b) with said flange of each outer facing sheet positioned inboard of and spaced-apart from said flange of each said inner facing sheet; and clip and fastener means engageable with the flanges of the outer facing sheets for securing said panels to certain of said sub-girts; the improvement in laterally adjustable connecting means providing a positive mechanical connection between the outer facing sheets of adjacent panels, comprising: said second side wall of each outer facing sheet having a recess formed integrally therein and saced-apart from said central web and from said flange, said recess comprising confronting first and second interior wall segments extending generally parallel with said central web, and a connecting wall segment; and a complementary tongue formed integrally with said first side wall of each outer facing sheet and extending outwardly therefrom into the recess of the adjacent facing sheet, said complementary tongue comprising a first exterior wall segment confronting said first interior wall segment and being generally parallel therewith, and a second exterior wall segment adjoining said first exterior wall segment to provide a leading edge remote from said first side wall; the width of said complementary tongue and the depth of said recess being such that prior to securing said panels to said subgirts, the position of each panel may be adjusted laterally with respect to the previously erected panel, thereby to conform the lateral coverage provided by all of said panels with that required by said structural framework.

2. The improvement of claim 1 including a sealant material applied to the first interior wall segment of said recess, said sealant material being penetrated by said leading edge of the adjacent facing sheet to prOvide a weathertight seal.

3. The improvement of claim 2 wherein said second exterior wall segment forms an acute angle with said first exterior wall segment.

4. The improvement of claim 2 wherein the first interior wall segment of said recess is positioned adjacent to said central web.

5. The improvement of claim 1 wherein the spacing between the first and second side walls of the outer facing sheets of adjacent panels is uniform throughout said wall structure.

6. The improvement of claim 1 wherein said second and first side walls of each said inner facing sheet are provided with a said recess and a said complementary tongue, whereby laterally adjustable positive mechanical connections also are provided between the inner facing sheets of adjacent panels.

Images