Resizable Insulated and Watertightness Wall Panel Joint Structure

Abstract

This invention relates to a prefabricated insulated wall panel system with a resizable structure that can readily meet the on-site substrate dimensional tolerance by enabling the panel connectors to be cut, tailored on-site, and inserted and patched without damaging the watertightness structure as well as the continuous insulation structure of the exterior cladding system. In particular, the invention discloses the structure of the watertightness and insulated connectors at the joint of two adjacent insulated wall panels, wherein the panel positioning plate, functioning as a panel-to-panel watertightness connector and panel locker, is embraced by the two grooves at edges of the two adjacent panels, and installed in the grooves to interlock the two adjacent wall panels to accomplish watertightness structure, while wherein the insulated panel patch, functioning as a panel-to-panel continuous insulation patch, is patched on the back of the panel positioning plate to accomplish continuous insulation structure at joints of the panels. The invention also discloses that both of the said plate and patch can be tailored on-site upon the measurement variance of substrate wall at the panel joint to accomplish the seamless panel installation without damage watertightness and continuous insulation structure.

1 . A prefabricated exterior insulated wall panel system with a structure comprising: a prefabricated insulated wall panel, a groove on the edge of the said panel, a panel positioning and interlocking plate, an insulated panel patch, panel clips for the said plate or panel patch, clip fasteners, and a watertightness sealant. 
     
     
         2 . The prefabricated insulated wall panel of  claim 1 , wherein the said panel consists of four layers, the finish coat layer for aesthetic decoration, the mesh reinforced base coat layer for impact and scratch resistance and water barrier performance, the insulation core layer for thermal performance, and the backer layer for the panel to perform better with adhesive materials behind it to achieve tensile resistance. 
     
     
         3 . The prefabricated insulated wall panel of  claim 1 , wherein the said insulation core layer can be created in various commonly used insulation materials, such as polystyrene foam, expanded polystyrene foam, extruded polystyrene foam, polyurethane foam, polyurethane rigid foam, polyethylene foam, rock wool board, glass fiber board, etc. 
     
     
         4 . The prefabricated insulated wall panel of  claim 1 , wherein the said panel has four edges, namely top, bottom, left and right panel edge. 
     
     
         5 . The groove on the edge of the said panel in  claim 1 , wherein the groove divides the top and bottom edges of the said panel into two subareas, the inner edge area and outer edge area, and wherein the said outer edge area locating to the back of the panel with a larger dimension, and the said inner edge area locating to the front of the panel with a smaller dimension. 
     
     
         6 . The outer edge area at panel edge of  claim 5 , wherein the surface of said outer edge area is not covered with base coat layer, therefore the height of said outer edge from panel's bottom to its top is resizable by cutting it or patching it to the size required on the job site. 
     
     
         7 . The inner edge area at panel edge of  claim 5 , wherein the surface of said inner edge area is covered with base coat layer, therefore the size of the inner edge is not resizable either by cutting or patching. 
     
     
         8 . The inner edge area at panel top or bottom edge of  claim 5 , wherein a premade groove is carved into the said inner edge and located to the front of the panel, and wherein the back wall, front wall and floor of the said groove is covered by the base coat layer. 
     
     
         9 . The panel positioning and interlocking plate of  claim 1 , wherein the size of said plate is resizable by cutting on-site according to the job site panel sizing requirements, and during the installation of the panels the said plate is inserted into the groove on the lower panel's top edge, and then embraced by the groove on the upper panel's bottom edge. 
     
     
         10 . The panel positioning and interlocking plate of  claim 1 , wherein thickness of said plate plus the thickness of the said clips of  claim 1  shall match the thickness of the said groove, and the material of the plate must work well with the material of base coat layer on the groove surface to accomplish the watertightness capability. 
     
     
         11 . (canceled) 
     
     
         12 . The insulated panel patch of  claim 1 , wherein the said patch consists of three layers, a front layer made in a material that works well with the material of the said plate, an insulation core layer that directly connects to the outer edges of the adjacent panels to achieve continuous insulation capability, and a backer layer that performs well with adhesive materials behind it to achieve tensile resistance. 
     
     
         13 . The insulated panel patch of  claim 1 , wherein the size of said patch is resizable by cutting itself on-site according to the space required between the outer edges of the two adjacent panels during the installation. 
     
     
         14 . (canceled) 
     
     
         15 . The watertightness sealant of  claim 1 , wherein the said watertightness sealant can be used at the seams between the said plate and said panels to further accomplish the watertightness capability, and wherein the same finish color as panel finish coat can be used for the said sealant to further accomplish panel joint seamless visual effect. 
     
     
         16 . The panel clips of  claim 1 , wherein the honeycomb holes are pre-drilled across it to allow the said watertightness sealant to connect to the said plate through the holes while the metal fasteners are used to directly fasten it to the panel supporting frame. 
     
     
         17 . The panel clips of  claim 1 , wherein, when the said patch is used and the said plate cannot be covered by the said waterightness sealant due to the architectural constraints, the size of the clips is extended so as to cover the edges of the adjacent panels and the entire panel patch. 
     
     
         18 . The panel clips of  claim 1 , wherein, when the said patch and the extended said panel plates are used to accomplish some architectural facades, the said clips are fastened directly against panel edges and panel patch, and concealed by the extended said panel plates.