Composite joinery

• US 6,968,659 B2
• Filed: 02/27/2001
• Issued: 11/29/2005
• Est. Priority Date: 11/19/1998
• Status: Expired due to Term

• Current Assignee: NCI Group Incorporated (Cornerstone Building Brands, Inc.)
• Original Assignee: Centria, Inc. (Cornerstone Building Brands, Inc.)
• Inventors: Boyer, Keith
• Primary Examiner(s): Safavi, Michael
• Application Number:
  US09/794,569
• Publication Number:
  US 20010009085A1
• Time in Patent Office: 1,736 Days
• Field of Search: 522/35, 525/39, 525/33, 525/41, 525/23, 525/24, 525/25, 523/024, 523/023, 525/19, 523/094, 523/098, 523/021, 523/026
• US Class Current: 52/302.4
• CPC Class Codes: E04C 2/292 composed of insulating material and sheet metal

Abstract

A horizontal joint between upper and lower building panels, as well as a building wall including such a horizontal joint, in which a liquid diverting arrangement includes a gutter with first and second ends and at least one aperture disposed between these ends. Also contemplated are a method and apparatus for forming at least two building panels, in which the panels have different reveal dimensions, and a method and apparatus for forming a building panel in which a first reveal portion is registered while a second reveal portion has been formed at a preselected distance therefrom. Further contemplated are a method and kit for customizably assembling a building wall, in which panels having different thickness dimensions can be interchangeably connected with one another, as well as a method and kit for customizably assembling a building wall, in which on or more decorative profile panels and one or more structural building wall panels can be interchangeably connected with one another.

Claims

1. A building wall comprising:

an upper building panel and a lower building panel;

said lower panel comprises at least one connector comprising at least one of;

at least one male connector and at least one female connector;

said upper panel comprises at least one connector comprising at least one of;

at least one male connector and at least one female connector;

at least one connector of said upper panel being connected with at least one connector of said lower panel to form an outer joint;

means for diverting liquid;

said liquid diverting means comprising a gutter;

said gutter having first and second ends;

said liquid diverting means further comprising at least one aperture disposed between said first and second ends of said gutter;

wherein said at least one aperture is adapted to provide fluid communication with the ambient atmosphere and provide pressure equalization for said gutter;

one of said upper and lower panels being a structural building wall panel comprising a structural core and at least one of a liner sheet and a face sheet;

the other of said upper and lower panels being a decorative profile panel configured for providing a dedicated aesthetic function and comprising at least one of a liner sheet and a face sheet;

said structural building wall panel comprising a first connection arrangement and a second connection arrangement;

said decorative profile panel comprising a third connection arrangement and a fourth connection arrangement;

said first connection arrangement and said fourth connection arrangement being adapted to connect with one another to effect a first connection scheme between said structural building wall panel and said decorative profile panel;

said second connection arrangement and said third connection arrangement being adapted to connect with one another to effect a second connection scheme between said structural building wall panel and said decorative profile panel;

said first connection arrangement further being adapted to connect with a connection arrangement similar to said second connection arrangement present on another structural building wall panel;

said second connection arrangement further being adapted to connect with a connection arrangement similar to said first connection arrangement present on another structural building wall panel;

said at least one connector of said upper panel comprising at least one of said first, second, third and fourth connecting arrangements;

said at least one connector of said lower panel comprising at least one of said first, second, third and fourth connecting arrangements;

said third connection arrangement further being adapted to connect with a connection arrangement similar to said fourth connection arrangement present on another decorative profile panel;

said fourth connection arrangement being adapted to connect with a connection arrangement similar to said third connection arrangement present on another decorative profile panel;

said first and third connection arrangements being configured substantially similarly to one another;

said second and fourth connection arrangements being configured substantially similarly to one another;

whereby said structural building wall panel is adapted for connection to another structural building wall panel having at least one of;

a connection arrangement similar to said first connection arrangement and a connection arrangement similar to said second connection arrangement;

further whereby said decorative profile panel is adapted for connection to another decorative profile panel having at least one of;

a connection arrangement similar to said third connection arrangement and a connection arrangement similar to said fourth connection arrangement;

said structural building wall panel and said decorative profile panel being connected to one another via one of;

a first connection, between said first and fourth connection arrangements; and

a second connection, between said second and third connection arrangements;

said one of said first and second connections involving said at least one connector of said upper panel being connected with said at least one connector of said lower panel to form an outer joint;

said first connection arrangement and said fourth connection arrangement being configured for generally defining an inner cavity upon interconnection with one another;

said second connection arrangement and said third connection arrangement being configured for generally defining an inner cavity upon interconnection with one another;

said decorative profile panel and said structural building wall panel each comprising a face sheet;

said face sheet of said decorative profile panel and said face sheet of said structural building wall panel being configured for being coplanar with one another upon connection of said structural building wall panel with said decorative profile panel;

said decorative profile panel and said structural building wall panel each comprising a face sheet;

said face sheet of said decorative profile panel and said face sheet of said structural building wall panel being formed from sheet metal;

said decorative profile panel comprising decorative indentations configured for providing a dedicated aesthetic function; and

said upper panel and said lower panel being of differing average thicknesses.

2. The building wall according to claim 1, wherein said structural building wall panel and said decorative profile panel are configured for collectively accommodating a field-installed seal which is migratable into said inner cavity.

3. The building wall according to claim 2, wherein:

said decorative profile panel and said structural building wall panel each comprise a face sheet; and

said face sheet of said decorative profile panel and said face sheet of said structural building wall panel are configured for being coplanar with one another upon connection of said structural building wall panel with said decorative profile panel;

whereby throughout said building wall a consistent barrier, with consistent sealing, is established against vapor pressure, air infiltration and water infiltration.

4. The building wall according to claim 1, whereby essentially the same physical and performance characteristics are realized as in a connection between two structural building wall panels.

5. The building wall according to claim 1, further comprising insulative material disposed within said decorative profile panel.

6. The building wall according to claim 5, wherein said insulative material comprises a sheet of insulative material.

7. The building wall according to claim 1, wherein said structural building wall panel and said decorative profile panel comprise face sheets which are formable via the same formation tooling.

8. The building wall according to claim 1, wherein said at least one aperture permits the substantially immediate vertical egress of liquid from said gutter.

9. The building wall according to claim 1, wherein said at least one aperture comprises at least two apertures.

10. The building wall according to claim 9, wherein said at least two apertures are distributed substantially evenly over the length of said gutter.

11. The building wall according to claim 1, further comprising an opening disposed at one end of said gutter, said opening comprising means for directing fluid to a vertical discharge channel.

12. The building wall according to claim 1, further comprising a reveal having a sloped drain shelf and having a depth that is no less than about ⅝

of the overall depth of at least one of said upper panel and said lower panel.

13. The building wall according to claim 1, wherein said at least one structural building wall panel comprises at least one composite foam building panel.

14. The building wall according to claim 1, further comprising an inner seal, wherein said at least one aperture is disposed outwardly of said inner seal.

15. A building wall comprising:

an upper building panel and a lower building panel;

said lower panel comprises at least one connector comprising at least one of;

at least one male connector and at least one female connector;

said upper panel comprises at least one connector comprising at least one of;

at least one male connector and at least one female connector;

at least one connector of said upper panel being connected with at least one connector of said lower panel to form an outer joint;

means for diverting liquid;

said liquid diverting means comprising a gutter;

said gutter having first and second ends;

said liquid diverting means further comprising at least one aperture disposed between said first and second ends of said gutter;

wherein said at least one aperture is adapted to provide fluid communication with the ambient atmosphere and provide pressure equalization for said gutter;

one of said upper and lower panels being a structural building wall panel comprising a structural core and at least one of a liner sheet and a face sheet;

the other of said upper and lower panels being a decorative profile panel configured for providing a dedicated aesthetic function and comprising at least one of a liner sheet and a face sheet;

said structural building wall panel comprising a first connection arrangement and a second connection arrangement;

said decorative profile panel comprising a third connection arrangement and a fourth connection arrangement;

said first connection arrangement and said fourth connection arrangement being adapted to connect with one another to effect a first connection scheme between said structural building wall panel and said decorative profile panel;

said second connection arrangement and said third connection arrangement being adapted to connect with one another to effect a second connection scheme between said structural building wall panel and said decorative profile panel;

said first connection arrangement further being adapted to connect with a connection arrangement similar to said second connection arrangement present on another structural building wall panel;

said second connection arrangement further being adapted to connect with a connection arrangement similar to said first connection arrangement present on another structural building wall panel;

said at least one connector of said upper panel comprising at least one of said first, second, third and fourth connecting arrangements;

said at least one connector of said lower panel comprising at least one of said first, second, third and fourth connecting arrangements;

said third connection arrangement further being adapted to connect with a connection arrangement similar to said fourth connection arrangement present on another decorative profile panel;

said fourth connection arrangement being adapted to connect with a connection arrangement similar to said third connection arrangement present on another decorative profile panel;

said first and third connection arrangements being configured substantially similarly to one another;

said second and fourth connection arrangements being configured substantially similarly to one another;

whereby said structural building wall panel is adapted for connection to another structural building wall panel having at least one of;

a connection arrangement similar to said first connection arrangement and a connection arrangement similar to said second connection arrangement;

further whereby said decorative profile panel is adapted for connection to another decorative profile panel having at least one of;

a connection arrangement similar to said third connection arrangement and a connection arrangement similar to said fourth connection arrangement;

said structural building wall panel and said decorative profile panel being connected to one another via one of;

a first connection, between said first and fourth connection arrangements; and

a second connection, between said second and third connection arrangements;

said one of said first and second connections involving said at least one connector of said upper panel being connected with said at least one connector of said lower panel to form an outer joint;

said first connection arrangement and said fourth connection arrangement being configured for generally defining an inner cavity upon interconnection with one another;

said second connection arrangement and said third connection arrangement being configured for generally defining an inner cavity upon interconnection with one another;

said decorative profile panel and said structural building wall panel each comprising a face sheet;

said face sheet of said decorative profile panel and said face sheet of said structural building wall panel being configured for being coplanar with one another upon connection of said structural building wall panel with said decorative profile panel;

said face sheet of said decorative profile panel and said face sheet of said structural building wall panel being formed from sheet metal;

said decorative profile panel comprising decorative indentations configured for providing a dedicated aesthetic function;

said structural building wall panel and said decorative profile panel being configured for collectively accommodating a field-installed seal which is migratable into said inner cavity;

said decorative profile panel and said structural building wall panel each comprising a face sheet;

said face sheet of said decorative profile panel and said face sheet of said structural building wall panel being configured for being coplanar with one another upon connection of said structural building wall panel with said decorative profile panel;

whereby throughout said building wall a consistent barrier, with consistent sealing, is established against vapor pressure, air infiltration and water infiltration;

whereby essentially the same physical and performance characteristics are realized as in a connection between two structural building wall panels

said building wall further comprising insulative material disposed within said decorative profile panel;

said insulative material comprising a sheet of insulative material;

said structural building wall panel and said decorative profile panel comprising face sheets which are formable via the same formation tooling;

said at least one aperture permitting the substantially immediate vertical egress of liquid from said gutter;

said at least one aperture comprising at least two apertures;

said at least two apertures being distributed substantially evenly over the length of said gutter;

said building wall further comprising an opening disposed at one end of said gutter, said opening comprising means for directing fluid to a vertical discharge channel;

said at least one structural building wall panel comprising at least one composite foam building panel;

said building wall further comprising an inner seal, wherein said at least one aperture is disposed outwardly of said inner seal.

16. The building wall according to claim 15, wherein said upper panel and said lower panel are of differing average thicknesses.

17. The building wall according to claim 15, further comprising a reveal having a sloped drain shelf and having a depth that is no less than about ⅝

of the overall depth of at least one of said upper panel and said lower panel.