Wall Panel Systems for Rigid Wall Panels

Abstract

Wall panel systems are provided. The systems use interlocking components to attach photovoltaic (PV), ceramic, or other rigid wall panels to an exterior wall of a building.

1 . A wall panel system for attaching multiple wall panels to an exterior building wall, each wall panel having a dead load, and the system comprising:
 a plurality of rigid wall panels;   a plurality of bracket assemblies configured to be fastened to the exterior wall;   a plurality of attachment clips configured to be fastened to respective bracket assemblies by a fastener and to carry the dead loads of the respective wall panels, each attachment clip having a central fastening surface fastened to the bracket assembly and a pair of integrally formed wing members extending outwardly from the central fastening surface;   a plurality of tile perimeter strips configured to reside along a rear surface of a respective wall panel, each tile perimeter strip comprising:
 a generally C-shaped member having a planar surface configured to reside along a rear surface of a respective wall panel, and 
 a receiving member integrally attached to the C-shaped member and having a slot adapted to engage and interlock one of the wing members of the attachment clip, thus operatively connecting a respective wall panel to the attachment clip and, thereby, to the wall; 
 wherein the system is configured to allow wall panels to be secured to respective bracket assemblies in any sequence. 
   
     
     
         2 . The attachment system of  claim 1 , wherein each panel comprises a plurality of photovoltaic cells for converting solar energy to electrical energy. 
     
     
         3 . The attachment system of  claim 2 , wherein each panel further comprises:
 a substantially flat exterior surface; and   an electrical cable for delivering electrical current from the plurality of photovoltaic cells.   
     
     
         4 . The attachment system of  claim 1 , wherein each panel is fabricated from a ceramic material. 
     
     
         5 . The attachment system of  claim 4 , wherein:
 each panel further comprises a substantially flat exterior surface; and   each panel is fabricated from a porcelain material to form a porcelain ceramic tile.   
     
     
         6 . The attachment system of  claim 4 , further comprising:
 a plurality of thin metallic sheets placed along and connected to the planar surface of the panel perimeter strips, wherein each of the plurality of ceramic panels is adhesively connected to a corresponding metallic sheet.   
     
     
         7 . The attachment system of  claim 1 , wherein:
 each bracket assembly comprises two back-to-back L-angle brackets fastened to each other to form a generally Z shaped assembly, a first end of which is for attachment to the wall and a second end of which is for fastening to an attachment clip; and   the pairs of wing members of the attachment clips extends outwardly from the central fastening surface in a substantially symmetrical manner.   
     
     
         8 . The attachment system of  claim 1 , wherein each C-shaped member further comprises a through-opening to permit the ingress and egress of air and moisture behind the rigid wall panels to provide a pressure-balanced and moisture-drained environment. 
     
     
         9 . The attachment system of  claim 1 , further comprising:
 a plurality of infill strips non-sealingly disposed within respective slots of the tile perimeter strips so as to cover the fastener, each infill strip being fabricated from a substantially rigid material comprising aluminum, aluminum and polyethylene, polyvinyl chloride (PVC), or combinations thereof.   
     
     
         10 . The attachment system of  claim 1 , wherein each fastener comprises a threaded fastener. 
     
     
         11 . The attachment system of  claim 1 , wherein each panel perimeter strip is pre-adhered to a wall panel before installation to the building wall. 
     
     
         12 . The attachment system of  claim 1 , further comprising:
 an isolation tape applied between each attachment clip and a corresponding bracket assembly.   
     
     
         13 . The attachment system of  claim 1 , wherein:
 each attachment clip comprises aluminum; and   each bracket assembly comprises steel.   
     
     
         14 . The attachment system of  claim 1 , wherein each tile perimeter strip is fabricated at least partially from anodized aluminum. 
     
     
         15 . The attachment system of  claim 1 , further comprising:
 a panel stiffener placed between opposing tile perimeter strips along the rear surface of each wall panel to reinforce each wall panel.   
     
     
         16 . The attachment system of  claim 1 , further comprising:
 an adhesive applied to the rear surface of each wall panel and adhered to each tile perimeter strip along the planar surface, wherein the adhesive comprises structural silicone adhesive, bonding tape, or combinations thereof.   
     
     
         17 . The attachment system of  claim 16 , wherein:
 the adhesive is a structural silicone adhesive applied to the rear surface of each wall panel; and   the adhesive on each rear surface resides adjacent a strip of foam tape.   
     
     
         18 . A photovoltaic (PV) wall panel system for attaching multiple PV wall panels to an exterior building wall, each PV wall panel having a dead load, and the system comprising:
 a plurality of PV wall panels, each PV wall panel comprising a plurality of photovoltaic cells for converting solar energy to electrical energy;   a plurality of bracket assemblies configured to be fastened to the exterior building wall;   a plurality of attachment clips configured to be fastened to respective bracket assemblies by a fastener and to carry the dead loads of the respective PV wall panels, each attachment clip having a central fastening surface fastened to the bracket assembly and at least one integrally formed wing member, each wing member extending from the central fastening surface;   a plurality of tile perimeter strips, each tile perimeter strip comprising:
 a generally C-shaped member having a planar surface configured to reside along a rear surface of a respective PV wall panel, and 
 a receiving member integrally attached to the C-shaped member having a slot adapted to engage and interlock one of the wing members of the attachment clip; and 
   an adhesive for connecting the wall panels to the planar surfaces of the C-shaped members at least along selected edges; and   wherein the system is configured to allow the PV wall panels to be secured to respective bracket assemblies in any sequence.   
     
     
         19 . The attachment system of  claim 18 , further comprising:
 one or more cable guides attached to each bracket assembly, wherein each of the cable guides is configured to receive electrical cables extending from the rear surface of the PV wall panels for delivering electrical current from the plurality of photovoltaic cells.   
     
     
         20 . The attachment system of  claim 18 , further comprising:
 at least one panel stiffener fixed between the C-shaped members of opposing tile perimeter strips to provide support for each PV wall panel along the rear surface.   
     
     
         21 . The attachment system of  claim 18 , wherein the adhesive comprises structural silicone adhesive, strips of bonding tape, or combinations thereof. 
     
     
         22 . The attachment system of  claim 18 , wherein:
 the adhesive is a structural silicone adhesive applied to the rear surface of each wall panel; and   the adhesive on each rear surface resides adjacent a strip of foam tape.   
     
     
         23 . A hybrid wall panel system for attaching multiple wall panels to an exterior building wall, each wall panel having a dead load, and the system comprising:
 a plurality of bracket assemblies configured to be fastened to the exterior wall;   a plurality of attachment clips configured to be fastened to respective bracket assemblies by a fastener and to carry the dead loads of the respective wall panels, each attachment clip having a central fastening surface fastened to the bracket assembly and a pair of integrally formed wing members, each wing member extending from the central fastening surface;   a plurality of solar wall panels, each solar wall panel having a plurality of photovoltaic cells for converting solar energy to electrical energy;   a plurality of tile perimeter strips configured to be adhesively connected to a rear surface of a respective solar wall panel, each tile perimeter strip comprising:
 a generally C-shaped member having a planar surface configured to reside along a rear surface of a respective wall panel, and 
 a receiving member integrally attached to the C-shaped member and having a slot adapted to engage and interlock one of the wing members of the attachment clip, thus operatively connecting a respective wall panel to the attachment clip and, thereby, to the wall; 
   an adhesive for connecting the solar wall panels to the planar surfaces of the C-shaped members at least along selected edges;   a plurality of non-PV wall panels, each non-PV wall panel having an exterior flat surface and at least two side surfaces bent generally perpendicularly to the exterior flat surface and defining a hollow interior portion;   a plurality of panel perimeter strips configured to be fastened to one side surface of a respective non-PV wall panel, each panel perimeter strip comprising:
 a generally C-shaped member configured to extend reside inside of and reside along an inside portion of a side surface of a respective wall panel, and 
 a receiving member integrally attached to the C-shaped member configured to extend beyond the side surface of a wall panel and having a slot adapted to engage and interlock one of the wing members of the attachment clip, thus operatively connecting a respective wall panel to the attachment clip and, thereby, to the wall; 
   one or more rivets provided along the side surface of respective non-PV wall panels to connect the side surface to the receiving member of a respective panel perimeter strip;   wherein:
 the hybrid system is configured to allow non-PV wall panels to be secured to respective bracket assemblies in any sequence; 
 at least one solar wall panel is adjacent to at least one non-PV wall panel; and 
 the tile perimeter strips and the panel perimeter strips are dimensioned and configured such that the exterior surfaces of the solar wall panels and the non-PV wall panels are substantially flush with one another. 
   
     
     
         24 . The attachment system of  claim 23 , further comprising:
 at least one panel stiffener fixed between the C-shaped members of opposing tile perimeter strips to provide support for each PV wall panel along the rear surface.   
     
     
         25 . The attachment system of  claim 23 , wherein the adhesive comprises structural silicone adhesive, bonding tape, or combinations thereof. 
     
     
         26 . The attachment system of  claim 23 , wherein:
 the adhesive is a structural silicone adhesive applied to the rear surface of each wall panel; and   the adhesive on each rear surface resides adjacent a strip of foam tape.   
     
     
         27 . The attachment system of  claim 23 , wherein the system is configured to allow the solar wall panels to be secured to respective bracket assemblies in any sequence.