Process for making a sloped wall with a double gasket assembly

Abstract

1. A process for creating a sloped wall with a sealed joint between two concrete wall panels comprising a first wall panel, a double gasket assembly, and a second wall panel, the double gasket assembly comprising an inner gasket, a support coupling, and a weather gasket, the support coupling being attached to a first end face of the first wall panel by a metal channel, the first and second wall panels being aligned adjacent to one another in the same plane with the support coupling positioned between the first end face of the first wall panel and the second end face of the second wall panel, the second end face of the second wall panel being positioned a desired distance proximate to the first end face relative to the first wall panel to form a desired width of the joint between the end faces, and the inner gasket and the outer weather gasket contacting and compressed against both the first and second end faces to seal the joint between the end faces.

Description

[Technical field]

[0001] FIELD OF THEINVENTION. The present invention relates to a panel module useful in the construction of buildings, including commercial concrete tilt wall construction. The panel module comprises panels provided with at least one double gasket assembly suitable for sealing the gaps between the panels and the panel module. As used herein, "panel" and "wall panel" are used interchangeably. [Background technology]

[0002] 2. Description of the Related Art: Tilt-wall construction is a building construction technique that typically uses concrete in the walls, and typically requires a short time to construct and is more cost-effective than many other construction techniques. In a typical construction, large reinforced concrete wall panels, which may span multiple floors, are first formed horizontally. A horizontal wooden frame is formed on the ground, typically having the desired wall height and width, and including openings for any windows, doors, or other desired openings in the wall. Reinforcement, such as a grid of rebar, is inserted into the frame, after which concrete is poured into the prepared frame, and the top surface of the poured concrete is surfaced as desired. After the concrete has hardened, the horizontal wall panel is then lifted or "tilted" into a vertical position, typically by a crane, and then secured in place until the remaining building walls and structural elements (roof, intermediate floors, etc.) are secured in place.

[0003] In buildings with multiple concrete wall panels, there is a challenge in sealing the vertical joints between the panels. These sealed joints must also meet design requirements and other desired performance expectations (e.g., thermal expansion and contraction, building sway and movement, water separation, and thermal efficiency).

[0004] The gaps between the end faces of individual wall panels, referred to herein interchangeably as "joints" or "inter-panel joints," have traditionally been sealed from the exterior of the building after the wall panels have been placed in place and stabilized, e.g., attached to a building support structure. In one conventional process, after the concrete panels are in a vertical position and stabilized, the gaps between the panels are first sealed by forcing a resilient support known as a backer rod into the gap from the exterior of the building. This backer rod then serves as a support for manually pouring a wet (liquid) sealant onto the outwardly facing surface of the backer rod from the exterior of the building. The inwardly facing surface of the backer rod may additionally be manually sealed in a similar manner with a wet (liquid) sealant from the interior of the building if a double seal is desired. The wet sealant fills at least a portion of the gap between the edges of the two abutting panels and, as the sealant cures, provides an essentially permanently fixed air and water seal supported by the backer rod.

[0005] A great deal of skill is required to form an effective air and water seal, sometimes at considerable heights and in unfavorable weather conditions. The long cure times of wet sealants can also impact construction schedules.

[0006] Therefore, what is needed is a method suitable for creating sloped walls for commercial sloped wall construction that provides a sealed joint between two wall panels with redundant sealing, and that creates a method of sealing inter-panel joints with less work to the outside of the wall to seal those joints. Summary of the Invention [Means for solving the problem]

[0007] The present invention relates to a process for making a panel module suitable for use in an inclined wall, the panel module comprising a first panel having an integral metal channel and a support coupling for a double gasket assembly, the first panel has a height and a thickness and has a first major surface and an opposing second major surface; the first panel further has a first end surface, the first end surface being generally perpendicular to both the first major surface and the opposing second major surface, the first end surface having a first end length, which is a height of the first panel, and a first end width, which is a thickness of the first panel; The process is a) preparing a formwork for casting a first panel, the formwork comprising at least one formwork wall for forming a first end surface; at least one of the form walls includes a metal channel anchor for forming an integral metal channel at a first end surface; the integral metal channel anchor is oriented such that the metal channel at the first end is parallel to a length of the first end; b) inserting structural reinforcement elements into the formwork and attaching the reinforcement elements to metal channel anchors; c) applying concrete to the form and allowing the concrete to harden to form a first panel having an integral metal channel secured to the concrete; d) removing the formwork; e) mounting a support coupling for a double gasket assembly on the metal channel, The support coupling comprises a base, the base having a top surface and a bottom surface; The upper surface further includes an inner gasket support and an outer gasket support; The bottom surface of the base has a contact area for stabilizing the support coupling on the end surface, and the bottom surface further has an attachment area for attaching the support coupling to the metal channel, the attachment area being at least one protrusion, and a step.

[0008] The present invention also relates to a process for making a sloped wall having a sealed abutment, the wall comprising a first wall panel, a double gasket assembly, and a second wall panel; The double gasket assembly includes an inner gasket, a support coupling, and a weather gasket; the first and second panels each having a height and a thickness, each having a first major surface and an opposing second major surface; the first panel further has a first end surface, the first end surface being generally perpendicular to both the first major surface and the opposing second major surface of the first panel, the first end surface having a first end surface length that is a height of the first panel and a first end surface width that is a thickness of the first panel; the second panel further has a second end surface, the second end surface being generally perpendicular to both the first major surface and the opposing second major surface of the second panel, the second end surface having a second end surface length that is a height of the second panel and a second end surface width that is a thickness of the second panel; The process is a) preparing a horizontally oriented form for casting a first panel, the form comprising at least one form wall for forming a first end face, the at least one form wall including a metal channel anchor for forming an integral metal channel in the first end face, the integral metal channel anchor being oriented such that the metal channel in the first end face is parallel to a length of the first end face; b) inserting structural reinforcement elements into the formwork and attaching the reinforcement elements to metal channel anchors; c) applying concrete to the form and allowing the concrete to harden to form a horizontally oriented first panel having an integral metal channel secured to the concrete; d) removing the formwork; e) mounting a support coupling for a double gasket assembly on the metal channel, The support coupling comprises a base, the base having a top surface and a bottom surface; The upper surface further includes an inner gasket support and an outer gasket support; The bottom surface of the base has a contact area for stabilizing the support coupling on the end surface, the bottom surface further has an attachment area for attaching the support coupling to the metal channel, the attachment area being at least one protrusion; f) moving the horizontally oriented first panel from a horizontal to a vertical position, whereby the first end length having the support coupling for the double gasket assembly attached thereto is also oriented vertically; g) providing a second panel in a vertical position, the second end length also being oriented vertically; h) aligning the first and second wall panels such that a first major surface of the first wall panel and a first major surface of the second wall panel are in the same first plane, an opposing second major surface of the first wall panel and an opposing second major surface of the second wall panel are in the same second plane, the first and second planes forming a set of parallel major surface planes, a first end surface of the first wall panel and a second end surface of the second wall panel also forming a set of parallel end surface planes, and a support coupling of a dual gasket assembly attached to the first end surface is positioned between the first end surface of the first wall panel and the second end surface of the second wall panel within both the set of parallel major surface planes and the set of parallel end surface planes; moving the second wall panel relative to the first wall panel to move the second end face a desired distance proximate to the first end face to form a desired gap between the end faces; i) attaching a compressed inner gasket to an inner gasket support of a support coupling and attaching a compressed outer weather gasket to an outer gasket support of the support coupling; j) expanding or allowing the compressed inner gasket and the compressed outer weather gasket to expand and contact and compress against both the first end face of the first panel and the second end face of the second panel to seal the joint between the end faces of the two panels.

[0009] The invention additionally relates to a process for making a sloped wall having a sealed abutment, the wall comprising a first wall panel, a double gasket assembly, and a second wall panel; The double gasket assembly includes an inner gasket, a support coupling, and a weather gasket; the first and second panels each having a height and a thickness, each having a first major surface and an opposing second major surface; the first panel further has a first end surface, the first end surface being generally perpendicular to both the first major surface and the opposing second major surface of the first panel, the first end surface having a first end surface length that is a height of the first panel and a first end surface width that is a thickness of the first panel; the second panel further has a second end surface, the second end surface being generally perpendicular to both the first major surface and the opposing second major surface of the second panel, the second end surface having a second end surface length that is a height of the second panel and a second end surface width that is a thickness of the second panel; The process is a) preparing a horizontally oriented form for casting a first panel, the form comprising at least one form wall for forming a first end face, the at least one form wall including a metal channel anchor for forming an integral metal channel in the first end face, the integral metal channel anchor being oriented such that the metal channel in the first end face is parallel to a length of the first end face; b) inserting structural reinforcement elements into the formwork and attaching the reinforcement elements to metal channel anchors; c) applying concrete to the form and allowing the concrete to harden to form a horizontally oriented first panel having an integral metal channel secured to the concrete; d) removing the formwork; e) mounting a support coupling for a double gasket assembly on the metal channel, The support coupling comprises a base, the base having a top surface and a bottom surface; The upper surface further includes an inner gasket support and an outer gasket support; The bottom surface of the base has a contact area for stabilizing the support coupling on the end surface, the bottom surface further has an attachment area for attaching the support coupling to the metal channel, the attachment area being at least one protrusion; a compressed inner gasket is attached to an inner gasket support of the support coupling and a compressed outer weather gasket is attached to an outer gasket support of the support coupling, either before or after the support coupling is attached to the metal channel; f) moving the horizontally oriented first panel from a horizontal to a vertical position, whereby the first end length having the support coupling for the double gasket assembly attached thereto is also oriented vertically; g) providing a second panel in a vertical position, the second end length also being oriented vertically; h) aligning the first and second wall panels such that a first major surface of the first wall panel and a first major surface of the second wall panel are in the same first plane, an opposing second major surface of the first wall panel and an opposing second major surface of the second wall panel are in the same second plane, the first and second planes forming a set of parallel major surface planes, a first end surface of the first wall panel and a second end surface of the second wall panel also forming a set of parallel end surface planes, and a support coupling of a dual gasket assembly attached to the first end surface is positioned between the first end surface of the first wall panel and the second end surface of the second wall panel within both the set of parallel major surface planes and the set of parallel end surface planes; moving the second wall panel relative to the first wall panel to move the second end face a desired distance adjacent to the first end face to form a desired gap between the end faces; i) expanding the compressed inner gasket and the compressed outer weather gasket or allowing the compressed inner gasket and the compressed outer weather gasket to expand and contact and compress against both the first end face of the first panel and the second end face of the second panel to seal the joint between the end faces of the two panels.

[0010] The invention additionally relates to a process for making a sloped wall having a sealed joint, the wall comprising a first wall panel, a double gasket assembly, and a second wall panel, the double gasket assembly comprising an inner gasket, a support coupling, and a weather gasket; the first and second panels each having a height and a thickness, each having a first major surface and an opposing second major surface; the first panel further has a first end surface, the first end surface being generally perpendicular to both the first major surface and the opposing second major surface of the first panel, the first end surface having a first end surface length that is a height of the first panel and a first end surface width that is a thickness of the first panel; the second panel further has a second end surface, the second end surface being generally perpendicular to both the first major surface and the opposing second major surface of the second panel, the second end surface having a second end surface length that is a height of the second panel and a second end surface width that is a thickness of the second panel; The process is a) preparing a horizontally oriented form for casting a first panel, the form comprising at least one form wall for forming a first end face, the at least one form wall including a metal channel anchor for forming an integral metal channel in the first end face, the integral metal channel anchor being oriented such that the metal channel in the first end face is parallel to a length of the first end face; b) inserting structural reinforcement elements into the formwork and attaching the reinforcement elements to metal channel anchors; c) applying concrete to the form and allowing the concrete to harden to form a horizontally oriented first panel having an integral metal channel secured to the concrete; d) removing the formwork; e) moving the horizontally oriented first panel from a horizontal to a vertical position, whereby the first end length having the support coupling for the double gasket assembly attached thereto is also oriented vertically; f) providing a second panel in a vertical position, the second end length also being oriented vertically; g) aligning the first and second wall panels such that a first major surface of the first wall panel and a first major surface of the second wall panel lie in the same first plane, and an opposing second major surface of the first wall panel and an opposing second major surface of the second wall panel lie in the same second plane, the first and second planes forming a set of parallel major surface planes; the first end surface of the first wall panel and the second end surface of the second wall panel also form a pair of parallel end surface planes; a support coupling of the double gasket assembly attached to the first end surface is positioned between the first end surface of the first wall panel and the second end surface of the second wall panel within both the set of parallel main surface planes and the set of parallel end surface planes; moving the second wall panel relative to the first wall panel to move the second end face a desired distance proximate to the first end face to form a desired gap between the end faces; h) mounting a support coupling for a double gasket assembly to the metal channel, The support coupling comprises a base, the base having a top surface and a bottom surface; The upper surface further includes an inner gasket support and an outer gasket support; The bottom surface of the base has a contact area for stabilizing the support coupling on the end surface, the bottom surface further has an attachment area for attaching the support coupling to the metal channel, the attachment area being at least one protrusion; a compressed inner gasket is attached to an inner gasket support of the support coupling and a compressed outer weather gasket is attached to an outer gasket support of the support coupling, either before or after the support coupling is attached to the metal channel; i) expanding or allowing the compressed inner gasket and the compressed outer weather gasket to expand and contact and compress against both the first end face of the first panel and the second end face of the second panel to seal the joint between the end faces of the two panels. [Brief description of the drawings]

[0011] [Figure 1] FIG. 2 is a perspective view of an embodiment of a dual gasket assembly including a support coupling, a compressible inner gasket, and a compressible outer weather gasket. [Diagram 2] 1 is a perspective view of a joint between end faces of two panels, the joint having a length, width, and area. [Diagram 3] FIG. 2 is a cross-sectional view of one preferred embodiment of a support coupling for a dual gasket assembly. [Figure 4] FIG. 2 is a cross-sectional view of a preferred dual gasket assembly including a support coupling, a compressible inner gasket, and a compressible outer weather gasket. [Diagram 5] FIG. 13 is a cross-sectional view of one embodiment of the bottom surface of the base of the support coupling, where the attachment area is at least one protrusion. [Figure 6] FIG. 1 is a perspective view of a building illustrating one embodiment of multiple panels joined together to form the exterior of a building, showing a sloped wall formed from two panels and a sealed joint between the panels. [Figure 7] FIG. 1 is a perspective view of one representation of a panel 1 having a rectilinear shape and six sides, the six sides including two main faces and four end faces. [Figure 8] FIG. 1 is a perspective view of a panel having one possible type of C-channel formed on an end surface using metal C-channel anchors. [Figure 9] 1 shows a sequence of events illustrating the assembly of a tilt-wall concrete wall panel. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The present invention relates to sealing features and methods for sealing inter-panel joints, preferably inter-panel joints, in commercial wall construction, and products that include such sealing features along with features for drainage of any water that may collect within any such joints. As used herein, the phrases "inter-panel joint" and "inter-panel joint" are interchangeable and refer to the gap between the end faces of two adjacent panels, particularly in a wall system. The term panel is intended to include, but is not limited to, panels used as building wall components. The panels are preferably made of concrete, preferably reinforced concrete. Furthermore, unless otherwise indicated, there are no implied limitations on the orientation, design, or shape of the panels, and while many building walls are generally vertically oriented and rectangular, the invention described herein can be applied to all inter-panel joints of any orientation or type useful in buildings. The invention described herein can further relate to joint sealing mechanisms that are pre-installed on individual panels before the panels are assembled into a wall.

[0013] In particular, the invention disclosed herein relates to double gasket assemblies for sealing one or more joints and their use in panel modules and paneled wall systems, those panel modules and paneled walls, and other components used in those walls, as well as processes for making all of these inventions. In addition, the invention disclosed herein includes features specifically designed to manage and drain any water that may inadvertently collect in the double gasket assemblies.

[0014] In some preferred embodiments, these inventions are performed at a construction site and then used to construct the walls of a building. Intuitively, the use of these inventions should reduce the time required to construct and seal paneled walls at a construction site.

[0015] 6 is a perspective view of a simple building 60 illustrating one type of wall assembly, with individual panels 61, 62, and 63 each having a height H and width W, as shown, and sized and positioned sufficiently such that the only inter-panel joints are vertically oriented joints, e.g., lines 64a and 64b. Many combinations are possible, and the panels may span less than one story, one story, or more than one story of the structure. A wall assembly comprising wall panels may represent the entire skin (or exterior facade) of a building, or only a portion thereof.

[0016] As used herein, a sloped wall comprises at least a sealed joint between two concrete wall panels, the wall comprising a first wall panel, a double gasket assembly, and a second wall panel. The sealed joint is formed by a double gasket assembly between the two wall panels, the double gasket assembly comprising an inner gasket, a support coupling, and a weather gasket. Thus, as shown in Figure 6, the combination of wall panels 61 and 62 and the vertical joint 64a between the two panels sealed by the double gasket assembly forms a sloped wall.

[0017] Each of the first and second panels has a height and a thickness, and each has a first major surface and an opposing second major surface. Additionally, the first panel further has a first end surface, the first end surface being generally perpendicular to both the first major surface and the opposing second major surface of the first panel, the first end surface having a first end length that is the height of the first panel and a first end width that is the thickness of the first panel. The second panel further has a second end surface, the second end surface being generally perpendicular to both the first major surface and the opposing second major surface of the second panel, the second end surface having a second end length that is the height of the second panel and a second end width that is the thickness of the second panel.

[0018] The first panel is fabricated with a metal channel anchor forming an integral metal channel at the first end face, the integral metal channel anchor being oriented such that the metal channel at the first end face is parallel to the first end face length. A support coupling for the dual gasket assembly is additionally attached to the panel by the metal channel.

[0019] The support coupling comprises a base, the base having a top surface and a bottom surface, the top surface of the support coupling base further comprising an inner gasket support and an outer gasket support, the bottom surface of the support coupling base having a contact region for stabilizing the support coupling on the end surface and further comprising an attachment region for attaching the support coupling to the metal channel, the attachment region being at least one protrusion extending from the base and seated within the metal channel.

[0020] In the inclined wall, the first and second wall panels are aligned adjacent to each other such that the first major surface of the first wall panel and the first major surface of the second wall panel lie in the same first plane, and the opposing second major surface of the first wall panel and the opposing second major surface of the second wall panel lie in the same second plane, with the first and second planes forming a set of parallel major surface planes. In addition, the first end surface of the first wall panel and the second end surface of the second wall panel also form a set of parallel end surface planes. The support coupling of the double gasket assembly is attached to the first end surface and positioned between the first end surface of the first wall panel and the second end surface of the second wall panel. The support coupling is also positioned within both the set of parallel major surface planes and the set of parallel end surface planes.

[0021] In addition, the second end face of the second wall panel is positioned relative to the first wall panel at a desired distance proximate to the first end face to form a gap of a desired width between the ends. With the second wall panel in place, the inner and outer weather gaskets abut and are compressed against both the first end face of the first panel and the second end face of the second panel to seal the gap.

[0022] Figure 9 provides a conventional sequence of events illustrating the assembly of a tilt-wall concrete wall panel module from a horizontal position to a desired vertical position. First, the wall panel 80 is created horizontally by pouring concrete into a wooden form (not shown) having the desired features such as window and door openings. Typically, as shown, the wall is poured adjacent to the desired final vertical position of the wall panel, which in the case of Figure 9 is indicated by the dotted line 81, and which will ultimately be supported by footers 82. The wooden form is then removed after the concrete has hardened.

[0023] After the wooden formwork is removed, the double gasket assembly can be advantageously installed on the wall panel while it is still horizontal on the ground surface to form a wall panel module comprising the wall panel and the double gasket assembly. The horizontal stiffened wall panel module is then typically lifted into position by a crane using cables 84. Once the wall panel module is in position vertically and seated on the footer, temporary supports 85 are typically installed to maintain the wall module in position. Depending on the desired installation method of the wall system, additional wall panels or wall panel modules can be installed and temporarily supported in a similar manner. Permanent building features such as roof and floor supports 86 are installed to allow removal of the temporary supports 85 (as shown in dashed lines). The result is a wall system in which at least part of the sealing of the joints is achieved by compressing the two gaskets of the double gasket assembly between the end faces of the two panels in the surface area to be sealed on each panel.

[0024] In some embodiments, the invention relates to a process for making a panel module suitable for use in a sloped wall, the panel module comprising a first panel having an integral metal channel and a support coupling for a double gasket assembly, the first panel having a height and a thickness, and having a first major surface and an opposing second major surface, the first panel further having a first end surface, the first end surface being generally perpendicular to both the first major surface and the opposing second major surface, the first end surface having a first end length, which is the height of the first panel, and a first end width, which is the thickness of the first panel; The process is a) preparing a form for casting a first panel, the form comprising at least one form wall for forming a first end face, the at least one form wall including a metal channel anchor for forming an integral metal channel at the first end face, the integral metal channel anchor being oriented such that the metal channel at the first end face is parallel to a length of the first end face; b) inserting structural reinforcement elements into the formwork and attaching the reinforcement elements to metal channel anchors; c) applying concrete to the form and allowing the concrete to harden to form a first panel having an integral metal channel secured to the concrete; d) removing the formwork; e) attaching a support coupling for a double gasket assembly to a metal channel, the support coupling comprising a base, the base having a top surface and a bottom surface, the top surface further having an inner gasket support and an outer gasket support, the bottom surface of the base having a contact area for stabilizing the support coupling on the end surface, and the bottom surface further having an attachment area for attaching the support coupling to the metal channel, the attachment area being at least one protrusion.

[0025] Sealing of inter-panel joints utilizes a double gasket assembly. FIG. 1 is a perspective view of an embodiment of a double gasket assembly 10 comprising a support coupling 11, a compressible inner gasket 12, and a compressible outer weather gasket 14, not showing protrusions from the support coupling for attachment to a wall panel end face. The double gasket assembly is suitable for sealing a joint 20 between two panel end faces, as shown in FIG. 2, the joint having a length, width, and width. For clarity of illustration, FIG. 2 shows two panels rotated 90 degrees from a vertical position to a generally horizontal position, the two panels having two major faces 21 and 22, with a joint 20 (not drawn to scale) between the end faces, the end faces being perpendicular to the major faces of the panels. The joint length 23 is the length of the larger end face dimension that can be sealed, as measured parallel to the plane of the panels. The gap width 24 is the shorter edge dimension that can be sealed as measured perpendicular to both the gap length 23 and perpendicular to the plane of the panel; the gap width is essentially the thickness of the panel assuming the gap is between two panels of equal thickness. If the two panels are of different thickness, the gap width is the thickness of the thinner panel. The gap width 25 is the face-to-face distance between the two edges to be sealed. Although not drawn to scale in FIG. 2 for clarity of dimensional definition, the gap width 25 (the gap between the edges when the panel is installed in a wall) can be, and usually is, much smaller than the gap width 24 (which is usually the width of the panel). For example, the gap width 24 can be 4 to 8 inches, while the gap width 25 can be 1 / 2 to 1 inch.

[0026] Similarly, as shown in FIG. 1, the double gasket assembly has a generally elongated rectangular footprint on an end face of a wall panel and is configured to be attached to the end face of a wall panel, and therefore has a length 16, width 17, and width 18 measured in the same manner as a joint length 23, width 24, and width 25. Specifically, the length 16 of the double gasket assembly 10 is the overall length of the centerline of the long dimension of the double gasket assembly. That length, along with the individual lengths of the components of the double gasket assembly (support coupling 11, compressible inner gasket 12, and compressible outer weather gasket 14), are all measured generally parallel to the joint length 23 being sealed. The length 16 of the double gasket assembly, or a portion of the double gasket assembly, may be longer than, equal to, or shorter than the joint length 23. In particular, in some arrangements, it may be desirable for the length of the compressible inner gasket 12 and the compressible outer weather gasket 14 to be longer or shorter than any particular joint length 23, and for the length of the support coupling 11 to be either the same as or shorter than the joint length 23.

[0027] The width 17 of the double gasket assembly is the next largest linear dimension measured perpendicular to the length 16 of the double gasket assembly. The width 17 of the double gasket assembly is also the length parallel to the width 24 of the abutment. In some embodiments, the width 24 of the abutment is substantially greater than the width 17 of the double gasket assembly, and in some embodiments, the width 17 of the double gasket assembly is 50% or less of the width 24 of the abutment. In some embodiments, the width 17 of the double gasket assembly is 25% or less of the width 24 of the abutment.

[0028] The width 18 of the double gasket assembly is the thickness of the double gasket assembly and does not take into account any protrusions that may extend from the support coupling base. The thickness of the double gasket assembly as used herein is the distance between the outer contact surfaces of the gaskets, i.e., the outermost portions of each gasket that contact the end faces of each panel that form the joint. The term "original width" of the double gasket assembly, as used herein, is the width of the double gasket assembly before any compressive force is applied to the gaskets, in other words, when the gaskets are in a relaxed state. It is preferred that the double gasket assembly has an original width 18 that is greater than the width 25 of the joint between the two wall panels.

[0029] FIG. 3 is a cross-sectional or end view of one embodiment of a support coupling for a dual gasket assembly. The support coupling 30 comprises an elongated body having a base 31, the base having a top surface 32 and a bottom surface 33. The top surface of the base further comprises an inner gasket support 36 and an outer gasket support 37, the inner gasket support and the outer gasket support being on either side of the top surface of the base of the support coupling. A compressible inner gasket is then attached to the inner gasket support and a compressible outer weather gasket is attached to the outer gasket support (the gaskets are not shown attached in FIG. 3). In the embodiment of FIG. 3, both the inner gasket support 36 and the outer gasket support 37 have C-shaped gasket retaining cavities designed for use with a compressible inner gasket and a compressible outer weather gasket, a C-shaped channel that runs parallel to and the length of the support coupling of a dual gasket assembly, each gasket having a matching T-shaped protrusion. In some embodiments, the support coupling has a length parallel to the length of the double gasket assembly that corresponds to the length of the gap between the end faces of the two wall panels to be sealed.

[0030] The bottom surface 33 of the base 31 of the support coupling 30 has contact areas 35 on either side of a T-shaped protrusion 38 that stabilizes the support coupling on the end face of one of the two wall panels. This bottom surface also has an attachment area for attaching the support coupling to the end face, the attachment area having at least one protrusion that can seat in a metal channel in the end face of the panel to attach the support coupling to the panel. The support coupling of FIG. 3 has a base attachment area 34, which can be considered as an area on the bottom surface of the base, in the plane of the bottom surface on the base, that provides attachment of the support coupling to the end face. The protrusion 38 shown in FIG. 3 has a "T" shape and is designed to slide or fit into a C-shaped channel in the end face of the panel.

[0031] 4 is a cross-sectional view of a preferred dual gasket assembly 40 including a support coupling 41, a compressible inner gasket 42, and a compressible outer weather gasket 43. In this embodiment, the compressible inner gasket 42 and the compressible outer weather gasket 43 have a hollow flat hourglass shape with the flat or straight sides (contact faces) of the hourglass configured to match the flat end faces of the panels being sealed. The compressible inner gasket and the compressible outer weather gasket are attached to the support coupling via gasket supports (45 and 46) on opposite ends of the support coupling.

[0032] Mounting a compressible inner gasket and a compressible outer weather gasket on either side of the support coupling provides the advantage of a redundant gasket system, with the compressible outer weather gasket generally facing the exterior environment of the wall, while the compressible inner gasket generally facing the interior environment of the wall.

[0033] In the embodiment shown in FIG. 4, both the inner gasket support 45 and the outer gasket support 46 have C-shaped gasket retaining cavities, and the compressible inner gasket 42 and the compressible outer weather gasket 43 each have a matching T-shaped protrusion 47 that seats within each C-shaped cavity.

[0034] FIG. 4 further illustrates the width and breadth dimensions of the double gasket assembly, both of which may be measured perpendicular to the length of the double gasket assembly. The width of the double gasket assembly is dimension 400 in FIG. 4, which is the dimension parallel to the width dimension of the gap to be sealed, with the compressible inner gasket 42, the support coupling 41, and the compressible outer weather gasket 43 all contributing to the width of the double gasket assembly. That is, the width of the double gasket assembly is the distance from the outer periphery of the compressible inner gasket to the outer periphery of the compressible outer weather gasket, as shown. The original breadth of the double gasket assembly, i.e., the double gasket assembly with the gaskets in an uncompressed state, is also illustrated in FIG. 4. In some embodiments, the double gasket assembly has a width as measured perpendicular to both the length and breadth of the double gasket assembly, with the width measured from the maximum outer periphery of the compressible inner gasket to the maximum outer periphery of the compressible outer weather gasket, which is generally less than the width of the gap between the two wall panels.

[0035] The original width of the double gasket assembly is the thickness of the double gasket assembly before any compression of the gaskets in sealing the joints, i.e., when the gaskets are in a relaxed state. The original width is the distance between the outermost portions of each gasket that contact the end faces of the panel, and is shown by dimension 401 in FIG. 4. In that figure, the flat end faces shown on the compressible inner gasket and the flat end faces shown on the compressible outer weather gasket are the outermost portions from which the original width is measured. For purposes of this specification, the width of the double gasket assembly is measured excluding any protrusions extending from the base, and only the gasket measurements are considered. Furthermore, although gaskets having flat faces are shown in the figures, other shapes are possible, in which case the original width of the double gasket assembly is the maximum thickness of the uncompressed gasket as measured perpendicular to the base of the supporting coupling.

[0036] To form a seal, the double gasket assembly has an original width that is greater than the width of the gap between the two panels that it is sealing. Once the double gasket assembly seals the gap between the two panels, the installation width of the double gasket assembly is preferably the same as the width of the gap between the two panels.

[0037] The inner gasket supports (36, 45) and the outer gasket supports (37, 46) are preferably made integral with the support coupling base. If desired, each of the gasket supports can also be made integral with its associated gasket. However, in some embodiments it may be desirable to have only the compressible inner gasket integral with the gasket supports, and leave the compressible outer weather gasket removable from the supports so that it can be replaced as necessary due to weathering.

[0038] In the embodiment of the support coupling and dual gasket assembly shown in Figures 3 and 4, each inner gasket support (36, 45) and outer gasket support (37, 46) has a gasket retaining cavity for mounting a compressible inner gasket 42 and a compressible outer weather gasket 43, respectively, via a gasket retaining projection 47 extending from each of the respective gaskets. However, either or both of the gasket supports in a set can have a gasket retaining projection for mounting its respective gasket, with each gasket having a matching cavity for seating the associated gasket retaining projection.

[0039] Specifically, in some embodiments, the compressible inner gasket of the dual gasket assembly is attached to the inner gasket support by: i) a protrusion extending from an inner gasket support that seats within a cavity in the compressible inner gasket; or ii) a projection extending from a compressible inner gasket that seats within a cavity in the inner gasket support.

[0040] In some embodiments, the compressible outer weather gasket of the dual gasket assembly is attached to an outer gasket support by: i) a protrusion extending from an outer gasket support that seats within a cavity in a compressible outer weather gasket; or ii) by a projection extending from a compressible outer weather gasket which seats within a cavity in the outer gasket support.

[0041] In some preferred embodiments, the inner gasket support and the outer gasket support each have at least one protrusion or cavity for mounting of the gasket. As used herein, a "protrusion" extending from a part means that the part has an appendage extending (or protruding) from the part having an appropriate size and shape that can be inserted into and seated in an appropriately sized and shaped cavity in a second part to connect or attach the two parts together. In some embodiments, the protrusion can have any shape typically used for darts, such as those known as "darts" and known in the art, such as an arrow shape, a tree shape, a barbed shape, or a "T" shape. The cavity associated with each of these shapes is an opening in the part that allows the shape to enter and seat in that part.

[0042] "Seat" or "seated" means that a protrusion is mechanically held or maintained within a cavity to secure the protrusion within the cavity and connect or attach two parts to one another. Cavity means a pocket, channel, unfilled space, or perforated space in a surface of a part having a suitable size and shape that can receive and seat a protrusion of suitable size and shape.

[0043] If protrusions and cavities are used, they can further attach the double gasket assembly to the end face of the panel, and if the panel is moved, each gasket and gasket support must be properly attached together so that the gaskets remain attached, and further, the gaskets can be compressed between two adjacent end faces without either gasket being removed from its gasket support. Alternatively, the support coupling can be attached to the end face of the panel first, and then each gasket can be attached by any combination of protrusions and cavities, and again, each gasket and gasket support must be properly attached together so that the gaskets remain attached if the panel is moved, and further, the gaskets can be compressed between two adjacent end faces without either gasket being removed from its gasket support.

[0044] Many different configurations of the protrusions and cavities are possible. For example, both linear configurations of linearly arranged sets of individually separated gasket darts and matching linearly arranged sets of individually separated gasket support cavities, oriented parallel to the length of the double gasket assembly when installed and essentially extending the length of the support coupling, can be used, with the number of attachment points being determined by the gasket application. In a preferred embodiment, the protrusions are continuous protrusions, meaning that they essentially extend the length of the support coupling, oriented parallel to the length of the double gasket assembly when installed. Similarly, a preferred embodiment is that the cavities are continuous channels, again meaning that they essentially extend the length of the support coupling, oriented parallel to the length of the double gasket assembly when installed.

[0045] In some preferred embodiments, the protrusion can have a cross-sectional "T" shape, which in turn can seat within a cavity having a cross-sectional "C" shape, as shown by the cross-sectional views of the support coupling and dual gasket assembly in Figures 3 and 4. The C-shaped cavity typically forms a channel on or within the support coupling base, which is oriented parallel to the length of the dual gasket assembly and preferably extends continuously along the length of the support coupling base. Similarly, the associated gasket has a T-shaped protrusion that preferably extends continuously along the length of the gasket.

[0046] Similarly, a T-shaped protrusion, which extends preferably continuously along the length of the base of the support coupling, seats in the C-shaped cavity and typically forms a channel on or in the end face of the wall panel, the channel being oriented parallel to the length of the end face length and preferably extending continuously along that end face length. Figure 8 shows a panel 90 having one possible type of C-shaped channel 91 formed in the end face using a metal C-channel anchor 91.

[0047] In some preferred embodiments, the compressible inner gasket and the compressible outer weather gasket have the same shape, one preferred shape being shown in FIG. 4 as a double lobed, hollow, flattened, hourglass shape, with the flattened or straight sides of the hourglass configured to match the planar edge of the panel being sealed. However, the shapes of the compressible inner gasket and the compressible outer weather gasket do not have to be the same. Other gasket shapes and materials are also contemplated as suitable for use herein. It is contemplated that many different gasket materials having a circular or near circular, curved, or rectangular or near rectangular cross section, or combinations thereof, may be used as gaskets in a double gasket assembly.

[0048] In a preferred embodiment, the gaskets and gasket supports are configured such that when the dual gasket assembly is attached to an end face of a wall panel, both the compressible inner gasket and the compressible outer weather gasket are not compressed against the end face. As shown in FIG. 4, the bottom contact surface 48 of each gasket aligns with the bottom surface of the base of the support coupling. This facilitates installation of the dual gasket assembly onto the end face of a wall panel.

[0049] For example, for the preferred embodiment shown in Figure 4, to install the dual gasket assembly on the end face of a wall panel, the support coupling can be attached to the end face first, and then the compressible inner gasket can be attached by sliding the T-shaped protrusion of the compressible inner gasket into the C-shaped inner gasket support of the support coupling. The compressible outer weather gasket can be attached to the outer gasket support in a similar manner. The base surface of the gasket is at most flush with the bottom surface of the support coupling so that the gasket can be slid into the C-shaped cavity in the support coupling without substantial friction from the end face of the wall.

[0050] Alternatively, both the compressible inner gasket and the compressible outer weather gasket can be attached to the support coupling by again sliding each T-shaped gasket protrusion into its associated C-shaped gasket support on the support coupling to create a fully assembled double gasket assembly, which can then be attached to the end face of the wall panel. Again, the base surface of the gasket is at most flush with the bottom surface of the support coupling, so the double gasket assembly can be installed without first compressing the gasket against the end face of the wall. Both of these techniques allow for easier and more accurate placement of the double gasket assembly onto the end face of the wall. Furthermore, this preferred gasket configuration still provides proper sealing of the joint, since both the compressible inner gasket and the compressible outer weather gasket are later compressed against both end faces of the joint by contact with a second end face from another wall to completely seal the joint.

[0051] Preferably, in the use of the double gasket assembly in the inclined wall, the compressible inner gasket is installed on the support coupling as a compressed inner gasket, and the compressible outer weather gasket is also installed on the support coupling as a compressed outer weather gasket. By "compressed" it is meant that the original area of ​​the gasket is reduced so that the gasket area is smaller than the gap to be sealed. In some embodiments, the area of ​​each of the compressed inner gasket and the compressed outer weather gasket can be 50% or more of the gap area.

[0052] Compressed inner gaskets and compressed outer weather gaskets are believed to be particularly useful in sloped wall construction because concrete sloped wall panels are quite large and heavy, which can damage the gaskets installed on the end faces of the wall panels during lifting and vertical positioning of the wall panels.

[0053] Thus, by casting a concrete wall panel having an integral metal channel that is fixed in the concrete, the end faces have a metal channel whereby a support coupling can be attached at any desired time during installation of the wall panel by sliding a protrusion from the support coupling base into the channel. For example, the support coupling can be attached to the channel while the wall panel is in a horizontal position before it is lifted to a vertical position, or the support coupling can be attached to the channel after the wall panel is lifted to a vertical position. In one preferred embodiment, the support coupling is attached to the channel after two adjacent panels have been lifted and positioned vertically in place, with the metal channel positioned on the end faces that make up one side of the gap between the panels. The support coupling can be slid down between the two end faces of the panels and a protrusion from the support coupling base is inserted into the channel to attach the support coupling to one of the end faces.

[0054] The use of a compressed inner gasket and a compressed outer weather gasket allows the gaskets to be installed as desired. For example, two compressed gaskets can be installed in the same manner by inserting the gasket projections into the C-shaped gasket support channel and sliding the compressed gasket onto the support coupling. Installation of the compressed gaskets can be done before the support coupling is installed on the wall, and the entire double gasket assembly is installed as described above for installation of only the support coupling while the wall panel is in a horizontal or vertical position, or preferably when the two concrete wall panels are already in place vertically with the desired joints.

[0055] That is, in a process for making a panel module, a compressed inner gasket is attached to an inner gasket support of the support coupling and a compressed outer weather gasket is attached to an outer gasket support of the support coupling prior to attaching the support coupling for the dual gasket assembly to the metal channel. In addition, after the compressed gaskets are attached, the process can include a step of expanding or allowing the compressed inner gasket and the compressed outer weather gasket to expand.

[0056] Alternatively, the compressed gasket can be installed after the support coupling is installed on the end face of the wall panel. That is, in the process for making a panel module, after the support coupling for the double gasket assembly is installed in the metal channel, the compressed inner gasket is attached to the inner gasket support of the support coupling and the compressed outer weather gasket is attached to the outer gasket support of the support coupling. In addition, after the compressed gasket is installed, the process can include a step of expanding or allowing the compressed inner gasket and the compressed outer weather gasket to expand.

[0057] Thus, in one embodiment, the invention relates to a process for making a sloped wall having a sealed abutment, the wall comprising a first wall panel, a double gasket assembly, and a second wall panel, the double gasket assembly comprising an inner gasket, a support coupling, and a weather gasket; the first and second panels each having a height and a thickness, each having a first major surface and an opposing second major surface; the first panel further has a first end surface, the first end surface being generally perpendicular to both the first major surface and the opposing second major surface of the first panel, the first end surface having a first end surface length that is a height of the first panel and a first end surface width that is a thickness of the first panel; the second panel further has a second end surface, the second end surface being generally perpendicular to both the first major surface and the opposing second major surface of the second panel, the second end surface having a second end surface length that is a height of the second panel and a second end surface width that is a thickness of the second panel; The process is a) preparing a horizontally oriented form for casting a first panel, the form comprising at least one form wall for forming a first end face, the at least one form wall including a metal channel anchor for forming an integral metal channel in the first end face, the integral metal channel anchor being oriented such that the metal channel in the first end face is parallel to a length of the first end face; b) inserting structural reinforcement elements into the formwork and attaching the reinforcement elements to metal channel anchors; c) applying concrete to the form and allowing the concrete to harden to form a horizontally oriented first panel having an integral metal channel secured to the concrete; d) removing the formwork; e) mounting a support coupling for a double gasket assembly on the metal channel, The support coupling comprises a base, the base having a top surface and a bottom surface; The upper surface further includes an inner gasket support and an outer gasket support; The bottom surface of the base has a contact area for stabilizing the support coupling on the end surface, the bottom surface further has an attachment area for attaching the support coupling to the metal channel, the attachment area being at least one protrusion; a compressed inner gasket is attached to an inner gasket support of the support coupling and a compressed outer weather gasket is attached to an outer gasket support of the support coupling, either before or after the support coupling is attached to the metal channel; f) moving the horizontally oriented first panel from a horizontal to a vertical position, whereby the first end length having the support coupling for the double gasket assembly attached thereto is also oriented vertically; g) providing a second panel in a vertical position, the second end length also being oriented vertically; h) aligning the first and second wall panels such that a first major surface of the first wall panel and a first major surface of the second wall panel are in the same first plane, an opposing second major surface of the first wall panel and an opposing second major surface of the second wall panel are in the same second plane, the first and second planes forming a set of parallel major surface planes, a first end surface of the first wall panel and a second end surface of the second wall panel also forming a set of parallel end surface planes, and a support coupling of a dual gasket assembly attached to the first end surface is positioned between the first end surface of the first wall panel and the second end surface of the second wall panel within both the set of parallel major surface planes and the set of parallel end surface planes; moving the second wall panel relative to the first wall panel to move the second end face a desired distance adjacent to the first end face to form a desired gap between the end faces; i) expanding the compressed inner gasket and the compressed outer weather gasket or allowing the compressed inner gasket and the compressed outer weather gasket to expand and contact and compress against both the first end face of the first panel and the second end face of the second panel to seal the joint between the end faces of the two panels.

[0058] Alternatively, the support coupling can be attached to the end face before the panel is lifted into a vertical position, and then after two adjacent panels are lifted and positioned vertically in place, a compressed gasket can be inserted, with the metal channel forming one side of the joint between the panels and positioned on the end face that has the support coupling attached.

[0059] The embodiment relates to a process for making a sloped wall having a sealed joint, the wall comprising a first wall panel, a double gasket assembly, and a second wall panel, the double gasket assembly comprising an inner gasket, a support coupling, and a weather gasket; the first and second panels each having a height and a thickness, each having a first major surface and an opposing second major surface; the first panel further has a first end surface, the first end surface being generally perpendicular to both the first major surface and the opposing second major surface of the first panel, the first end surface having a first end surface length that is a height of the first panel and a first end surface width that is a thickness of the first panel; the second panel further has a second end surface, the second end surface being generally perpendicular to both the first major surface and the opposing second major surface of the second panel, the second end surface having a second end surface length that is a height of the second panel and a second end surface width that is a thickness of the second panel; The process is a) preparing a horizontally oriented form for casting a first panel, the form comprising at least one form wall for forming a first end face, the at least one form wall including a metal channel anchor for forming an integral metal channel in the first end face, the integral metal channel anchor being oriented such that the metal channel in the first end face is parallel to a length of the first end face; b) inserting structural reinforcement elements into the formwork and attaching the reinforcement elements to metal channel anchors; c) applying concrete to the form and allowing the concrete to harden to form a horizontally oriented first panel having an integral metal channel secured to the concrete; d) removing the formwork; e) mounting a support coupling for a double gasket assembly on the metal channel, The support coupling comprises a base, the base having a top surface and a bottom surface; The upper surface further includes an inner gasket support and an outer gasket support; The bottom surface of the base has a contact area for stabilizing the support coupling on the end surface, the bottom surface further has an attachment area for attaching the support coupling to the metal channel, the attachment area being at least one protrusion; f) moving the horizontally oriented first panel from a horizontal to a vertical position, whereby the first end length having the support coupling for the double gasket assembly attached thereto is also oriented vertically; g) providing a second panel in a vertical position, the second end length also being oriented vertically; h) aligning the first and second wall panels such that a first major surface of the first wall panel and a first major surface of the second wall panel lie in the same first plane, and an opposing second major surface of the first wall panel and an opposing second major surface of the second wall panel lie in the same second plane, the first and second planes forming a set of parallel major surface planes; the first end surface of the first wall panel and the second end surface of the second wall panel also form a pair of parallel end surface planes; a support coupling of the double gasket assembly attached to the first end surface is positioned between the first end surface of the first wall panel and the second end surface of the second wall panel within both the set of parallel main surface planes and the set of parallel end surface planes; moving the second wall panel relative to the first wall panel to move the second end face a desired distance proximate to the first end face to form a desired gap between the end faces; i) attaching a compressed inner gasket to an inner gasket support of a support coupling and attaching a compressed outer weather gasket to an outer gasket support of the support coupling; j) expanding or allowing the compressed inner gasket and the compressed outer weather gasket to expand and contact and compress against both the first end face of the first panel and the second end face of the second panel to seal the joint between the end faces of the two panels.

[0060] In one preferred embodiment, the support coupling is attached to the channel in the end face after two adjacent panels are lifted and positioned vertically in place, with the metal channel positioned in the end face that constitutes one side of the gap between the panels. The support coupling is then slid down between the two end faces of the panels, and the protrusion from the base of the support coupling is inserted into the channel to attach the support coupling to one of the end faces. Each of the compressed inner gasket and compressed outer weather gasket are then slid down between the two end faces of the panels to form a double gasket assembly between the end faces of the two wall panels.

[0061] The embodiment relates to a process for making a sloped wall having a sealed joint, the wall comprising a first wall panel, a double gasket assembly, and a second wall panel, the double gasket assembly comprising an inner gasket, a support coupling, and a weather gasket; the first and second panels each having a height and a thickness, each having a first major surface and an opposing second major surface; the first panel further has a first end surface, the first end surface being generally perpendicular to both the first major surface and the opposing second major surface of the first panel, the first end surface having a first end surface length that is a height of the first panel and a first end surface width that is a thickness of the first panel; the second panel further has a second end surface, the second end surface being generally perpendicular to both the first major surface and the opposing second major surface of the second panel, the second end surface having a second end surface length that is a height of the second panel and a second end surface width that is a thickness of the second panel; The process is a) preparing a horizontally oriented form for casting a first panel, the form comprising at least one form wall for forming a first end face, the at least one form wall including a metal channel anchor for forming an integral metal channel in the first end face, the integral metal channel anchor being oriented such that the metal channel in the first end face is parallel to a length of the first end face; b) inserting structural reinforcement elements into the formwork and attaching the reinforcement elements to metal channel anchors; c) applying concrete to the form and allowing the concrete to harden to form a horizontally oriented first panel having an integral metal channel secured to the concrete; d) removing the formwork; e) moving the horizontally oriented first panel from a horizontal to a vertical position, whereby the first end length having the support coupling for the double gasket assembly attached thereto is also oriented vertically; f) providing a second panel in a vertical position, the second end length also being oriented vertically; g) aligning the first and second wall panels such that a first major surface of the first wall panel and a first major surface of the second wall panel lie in the same first plane, and an opposing second major surface of the first wall panel and an opposing second major surface of the second wall panel lie in the same second plane, the first and second planes forming a set of parallel major surface planes; the first end surface of the first wall panel and the second end surface of the second wall panel also form a pair of parallel end surface planes; a support coupling of the double gasket assembly attached to the first end surface is positioned between the first end surface of the first wall panel and the second end surface of the second wall panel within both the set of parallel main surface planes and the set of parallel end surface planes; moving the second wall panel relative to the first wall panel to move the second end face a desired distance proximate to the first end face to form a desired gap between the end faces; h) mounting a support coupling for a double gasket assembly to the metal channel, The support coupling comprises a base, the base having a top surface and a bottom surface; The upper surface further includes an inner gasket support and an outer gasket support; The bottom surface of the base has a contact area for stabilizing the support coupling on the end surface, the bottom surface further has an attachment area for attaching the support coupling to the metal channel, the attachment area being at least one protrusion; a compressed inner gasket is attached to an inner gasket support of the support coupling and a compressed outer weather gasket is attached to an outer gasket support of the support coupling, either before or after the support coupling is attached to the metal channel; i) expanding or allowing the compressed inner gasket and the compressed outer weather gasket to expand and contact and compress against both the first end face of the first panel and the second end face of the second panel to seal the joint between the end faces of the two panels.

[0062] As explained above, the compressed gasket has a reduced area that is smaller than the area of ​​the abutment gap, which allows the compressed gasket to be inserted after the abutment gap is formed, and in some embodiments, the area of ​​each of the compressed inner gasket and the compressed outer weather gasket can be 50% or more of the area of ​​the abutment. However, the compressed gasket should also be expandable and compressible so that when the compressed gasket is positioned in place, it can be compressed against both end faces of the abutment to seal the abutment.

[0063] Such compressed gaskets can be made by several processes, including compressing the gaskets radially to reduce their extent and then wrapping them with a lightweight plastic cover that holds the gasket in compression. The plastic cover can be provided with a tear strip that longitudinally tears the plastic wrap over the compressed gasket, allowing it to expand after it is positioned between two ends at a joint. This is essentially a mechanical method of keeping the gasket in compression, but any process can be used that can produce a compressed gasket that can further expand to compress against both ends that form the joint and seal the joint.

[0064] The compressible inner gasket and the compressible outer weather gasket can comprise any resilient material produced in a compressible form that can provide an adequate seal and is durable enough to withstand the rigors of construction. Particular panel applications may also have additional preferred requirements for the gasket material, such as thermal expansion and contraction characteristics within certain ranges, and the ability to remain flexible over time and changing temperatures to accommodate building sway and movement. It is also desirable for the compressible outer weather gasket to have adequate weather resistance, such as not being unduly affected by water and / or UV light.

[0065] Resilient materials contemplated as suitable for use in the compressible inner gasket and the compressible outer weather gasket include elastomeric and rubber materials including silicone and modified silicone elastomers, ethylene propylene diene monomer (EPDM) rubber, and other compressible crosslinked elastomers, as well as other flexible polyurethanes and polyethylenes, etc. The compressible forms of the gaskets can include open centers and relatively hollow or hollow lobed constructions, as shown in the present drawings, or various types of closed cell foams.

[0066] The compressible inner gasket and the compressible outer weather gasket in the double gasket assembly are significantly compressed at the sealed joint, and therefore in many embodiments, an open center, relatively hollow, or hollow lobed gasket construction is preferred. Specifically, the gaskets of the double gasket assembly are preferably permanently compressible such that the area of ​​the double gasket assembly in its compressed state at the sealed joint is at least 80% of its original area, preferably at least 75% of its original area, and most preferably at least 50% of its original area at the sealed joint.

[0067] In many embodiments, the contact area for stabilizing the support coupling on an end face is larger than the attachment area for attaching the support coupling to said end face, especially when the support coupling is attached to the end face with an attachment area that is a protrusion or a cavity. FIG. 5 is a cross-sectional view of one embodiment of the bottom surface of the base of the support coupling, where the attachment area is at least one protrusion. The support coupling 50 has two gasket supports 59 with darts. As shown, the support coupling 50 has a base attachment area 51 with at least one protrusion 52 that attaches the support coupling to the end face 53 of the panel (the dotted line indicates the location of the end face of the panel). The attachment area is considered to be the area on the bottom surface of the base, in the plane of the bottom surface on the base, that provides attachment of the support coupling to the end face.

[0068] The protrusion 52 shown in Figure 5 has a chamfered "T" shape and is designed to slide or fit into a C-shaped channel (or cavity) in the panel end face 53. In addition, Figure 5 shows a support coupling in which the contact area 54 for stabilizing the support coupling on the panel end face and the base attachment area 51 are not the same.

[0069] In some embodiments, the dual gasket assembly is adapted to seal a joint between a first surface region of a first end face of a first panel and a second surface region of a second end face of a second panel, where on the first panel, the first surface region to be sealed is a generally rectangular region on the first end face having a major axis with a first surface length and a minor axis with a first surface width, and on the second panel, the second surface region to be sealed is also a generally rectangular region on the second end face having a major axis with a second surface length and a minor axis with a second surface width.

[0070] 7 is a perspective view of a panel 71 having a rectilinear shape, the panel having six sides. The six sides include two main faces and four end faces. A first main face 72, which is the front side of the panel, and an opposite second main face 73, which is the back side of the panel, are shown. When the panel is used in the construction of a building, typically the first main face 72 (or front side) is the side of the panel that is exposed to the weather or is the side closest to and facing the exterior of the building, while the opposing second main face 73 (or back side) is the side of the panel that is the interior wall of the building or is the side closest to and facing the interior of the building.

[0071] The dual gasket assembly is used to seal a gap between a first end face of a first panel and a second end face of a second panel by sealing a first surface area of ​​the first end face of the first panel to a second surface area of ​​the second end face of the second panel. FIG. 7 shows a first surface area to be sealed on the first panel, which is the shaded area on the first end face of the panel. The first surface area has a major axis having a first surface length and a minor axis having a first surface width, the major axis being the longer dimension of the surface area on that end face and the minor axis being the shorter dimension of the surface area on that same end face. Similarly, although not shown, a second surface area to be sealed on the second end face of the second panel similarly has a major axis having a second surface length and a minor axis having a second surface width, the major axis being the longer dimension of the surface area on that end face and the minor axis being the shorter dimension of the surface area on that same end face.

[0072] Ultimately, the gap between this first surface area of ​​the first end face of the first panel and the second surface area of ​​the second end face of the second panel is sealed through the use of a double gasket assembly. For clarity, however, the features of the first panel will be considered first.

[0073] 7 shows a first edge 74 of a first panel, the first edge having a first edge area designated by corner point ABCD, the first edge being perpendicular or nearly perpendicular to both a first major surface 72 and an opposing second major surface 73 of the first panel, the first edge having a first surface area 75 to be sealed, designated by corner point AEFD.

[0074] The use of the phrase "surface area to be sealed" refers to the surface area on the end face of the panel that will include at least partial contact with the double gasket assembly after the gasket assembly is fully installed between the end faces of the two panels, thereby sealing the abutment gap. The double gasket assembly does not need to contact the entire width of the end face to seal the abutment. In many cases, the width of the double gasket assembly is not as wide as the thickness of the panel, and generally, it is desirable for the double gasket assembly to be positioned closer to the exterior surface (major surface 72) of the panel and the wall, rather than closer to the interior surface (major surface 73) of the panel and the wall, to seal the area as shown by the shading in FIG. 7. In some embodiments, it is desirable for the double gasket assembly to be positioned so that it is flush with the exterior surface (major surface 72) of the panel, giving the wall an essentially continuous surface appearance. In some other embodiments, it may be desirable to position the double gasket assembly so that it is not flush with the exterior surface of the panel, but is recessed inwardly between the panels from the exterior surface of the wall; this may provide a wall surface that further defines the panels and joints if that is the desired aesthetic appearance.

[0075] The first surface area 75 to be sealed further has a first surface length, represented by the distance between points AD or EF, since the surface is generally rectangular, and a first surface width, represented by the distance between points AE or DF, again since the surface is generally rectangular. Furthermore, the sealed surface area 75 shown in FIG. 7 is a preferred embodiment, and generally, the sealed surface area 75 has a first surface width AE or DF that is smaller than the width AB or DC of the entire first edge, and the sealed surface area 75 is located closer to the front side (major surface 72) of the panel than to the back side (major surface 73) of the panel. However, the first surface width AE or DF of the surface area 75 may be the same width as the first edge 74, or the first surface width AE or DF may be positioned at any point within the width of the first edge 74.

[0076] In typical straight wall construction, the first major surface 72 of a first panel lies in an exterior plane extending in all directions from the panel, and the first major surfaces of multiple other such panels form the exterior wall surface. Similarly, the opposing second major surface 73 of the first panel lies in an interior plane extending in all directions from the panel, and the second major surfaces of multiple other such panels form the interior wall surfaces.

[0077] While not repeated herein for the sake of brevity, any of the features, options, and elements described herein for any of the components or steps may be applied to a process for creating a paneled wall having sealed joints.

Claims

1. A process for creating a panel module suitable for use in an inclined wall, the panel module comprising a first panel having an integrated metal channel and a support coupling for a double gasket assembly, The first panel has height and thickness, and has a first main surface and an opposing second main surface. The first panel further has a first end face, the first end face being substantially perpendicular to both the first main surface and the opposing second main surface. The first end face has a first end face length which is the height of the first panel and a first end face width which is the thickness of the first panel. The aforementioned process, a) A step of preparing a formwork for casting the first panel, wherein the formwork comprises at least one formwork wall for forming the first end face, The at least one formwork wall includes a metal channel anchor for forming the integrated metal channel at the first end face, The integrated metal channel anchor is oriented such that the metal channel at the first end face is parallel to the length of the first end face. b) Inserting the structural reinforcing element into the formwork and attaching the reinforcing element to the metal channel anchor, c) The steps of pouring concrete into the formwork, allowing the concrete to harden, and forming a first panel having an integrated metal channel fixed to the concrete, d) The step of removing the formwork, e) The step of attaching the support coupling for the double gasket assembly to the metal channel, The support coupling comprises a base, and the base has an upper surface and a bottom surface. The upper surface further includes an inner gasket support and an outer gasket support. A process comprising the steps: the bottom surface of the base having a contact area for stabilizing the support coupling on the end surface, the bottom surface further having a mounting area for attaching the support coupling to the metal channel, the mounting area being at least one projection.

2. A process for creating an inclined wall having a sealed joint, wherein the wall comprises a first wall panel, a double gasket assembly, and a second wall panel. The double gasket assembly comprises an inner gasket, a support coupling, and a weather gasket. The first and second panels each have height and thickness, and each has a first main surface and an opposing second main surface. The first panel further has a first end face, the first end face being substantially perpendicular to both the first main surface and the opposing second main surface of the first panel, and the first end face having a first end face length which is the height of the first panel and a first end face width which is the thickness of the first panel. The second panel further has a second end face, the second end face being substantially perpendicular to both the first main surface and the opposing second main surface of the second panel, the second end face having a second end face length which is the height of the second panel, and a second end face width which is the thickness of the second panel. The aforementioned process, a) A step of preparing a horizontally oriented formwork for casting the first panel, the formwork comprising at least one formwork wall for forming the first end face, The at least one formwork wall includes a metal channel anchor for forming the integrated metal channel at the first end face, The integrated metal channel anchor is oriented such that the metal channel at the first end face is parallel to the length of the first end face. b) Inserting the structural reinforcing element into the formwork and attaching the reinforcing element to the metal channel anchor, c) A step of pouring concrete into the formwork and allowing the concrete to harden to form a horizontally oriented first panel having an integrated metal channel fixed to the concrete, d) The step of removing the formwork, e) The step of attaching the support coupling for the double gasket assembly to the metal channel, The support coupling comprises a base, and the base has an upper surface and a bottom surface. The upper surface further includes an inner gasket support and an outer gasket support. The bottom surface of the base has a contact area for stabilizing the support coupling on the end surface, and the bottom surface further has a mounting area for attaching the support coupling to the metal channel, and the mounting area is at least one protrusion. f) A step of moving the horizontally oriented first panel from a horizontal to a vertical position, wherein the first end face length to which the support coupling for the double gasket assembly is attached is also oriented vertically. g) A step of providing a second panel in a vertical position, wherein the length of the second end face is also oriented vertically, h) Aligning the first and second wall panels such that the first principal surface of the first wall panel and the first principal surface of the second wall panel are located on the same first plane, the opposing second principal surface of the first wall panel and the opposing second principal surface of the second wall panel are located on the same second plane, and the first and second planes form a pair of parallel principal planes, The first end face of the first wall panel and the second end face of the second wall panel also form a pair of parallel end face planes. The support coupling of the double gasket assembly, which is attached to the first end face, is positioned between the first end face of the first wall panel and the second end face of the second wall panel, within both a pair of parallel main planes and a pair of parallel end planes. The steps include: moving the second wall panel relative to the first wall panel so that the second end face is moved to a desired distance close to the first end face, thereby forming a desired width for the joint between the end faces; i) The steps of attaching the compressed inner gasket to the inner gasket support of the support coupling and attaching the compressed outer weather gasket to the outer gasket support of the support coupling, j) The step of expanding the compressed inner gasket and the compressed outer weather gasket, or enabling them to expand, so as to contact and compress them against both the first end face of the first panel and the second end face of the second panel, thereby sealing the joint between the end faces of the two panels, process.

3. A process for creating an inclined wall having a sealed joint, wherein the wall comprises a first wall panel, a double gasket assembly, and a second wall panel. The double gasket assembly comprises an inner gasket, a support coupling, and a weather gasket. The first and second panels each have height and thickness, and each has a first main surface and an opposing second main surface. The first panel further has a first end face, the first end face being substantially perpendicular to both the first main surface and the opposing second main surface of the first panel, and the first end face having a first end face length which is the height of the first panel and a first end face width which is the thickness of the first panel. The second panel further has a second end face, the second end face being substantially perpendicular to both the first main surface and the opposing second main surface of the second panel, the second end face having a second end face length which is the height of the second panel, and a second end face width which is the thickness of the second panel. The aforementioned process, a) A step of preparing a horizontally oriented formwork for casting the first panel, the formwork comprising at least one formwork wall for forming the first end face, The at least one formwork wall includes a metal channel anchor for forming the integrated metal channel at the first end face, The integrated metal channel anchor is oriented such that the metal channel at the first end face is parallel to the length of the first end face. b) Inserting the structural reinforcing element into the formwork and attaching the reinforcing element to the metal channel anchor, c) A step of pouring concrete into the formwork and allowing the concrete to harden to form a horizontally oriented first panel having an integrated metal channel fixed to the concrete, d) The step of removing the formwork, e) The step of attaching the support coupling for the double gasket assembly to the metal channel, The support coupling comprises a base, and the base has an upper surface and a bottom surface. The upper surface further includes an inner gasket support and an outer gasket support. The bottom surface of the base has a contact area for stabilizing the support coupling on the end surface, and the bottom surface further has a mounting area for attaching the support coupling to the metal channel, and the mounting area is at least one protrusion. The steps include: either before or after attaching the support coupling to the metal channel, a compressed inner gasket is attached to the inner gasket support of the support coupling, and a compressed outer weather gasket is attached to the outer gasket support of the support coupling; f) A step of moving the horizontally oriented first panel from a horizontal to a vertical position, wherein the first end face length to which the support coupling for the double gasket assembly is attached is also oriented vertically. g) A step of providing a second panel in a vertical position, wherein the length of the second end face is also oriented vertically, h) Aligning the first and second wall panels such that the first principal surface of the first wall panel and the first principal surface of the second wall panel are located on the same first plane, the opposing second principal surface of the first wall panel and the opposing second principal surface of the second wall panel are located on the same second plane, and the first and second planes form a pair of parallel principal planes, The first end face of the first wall panel and the second end face of the second wall panel also form a pair of parallel end face planes. The support coupling of the double gasket assembly, which is attached to the first end face, is positioned between the first end face of the first wall panel and the second end face of the second wall panel, within both a pair of parallel main planes and a pair of parallel end planes. The steps include moving the second wall panel relative to the first wall panel to move the second end face to a desired distance close to the first end face, thereby forming a desired width for the joint between the end faces, i) a step of expanding the compressed inner gasket and the compressed outer weather gasket, or allowing the compressed inner gasket and the compressed outer weather gasket to expand and contact and compress against both the first end face of the first panel and the second end face of the second panel, thereby sealing the joint between the end faces of the two panels, process.

4. A process for creating an inclined wall having a sealed joint, wherein the wall comprises a first wall panel, a double gasket assembly, and a second wall panel, the double gasket assembly comprising an inner gasket, a support coupling, and a weather gasket, The first and second panels each have height and thickness, and each has a first main surface and an opposing second main surface. The first panel further has a first end face, the first end face being substantially perpendicular to both the first main surface and the opposing second main surface of the first panel, and the first end face having a first end face length which is the height of the first panel and a first end face width which is the thickness of the first panel. The second panel further has a second end face, the second end face being substantially perpendicular to both the first main surface and the opposing second main surface of the second panel, the second end face having a second end face length which is the height of the second panel, and a second end face width which is the thickness of the second panel. The aforementioned process, a) A step of preparing a horizontally oriented formwork for casting the first panel, wherein the formwork comprises at least one formwork wall for forming the first end face, the at least one formwork wall includes a metal channel anchor for forming an integrated metal channel at the first end face, and the integrated metal channel anchor is oriented such that the metal channel at the first end face is parallel to the length of the first end face, b) Inserting the structural reinforcing element into the formwork and attaching the reinforcing element to the metal channel anchor, c) A step of pouring concrete into the formwork and allowing the concrete to harden to form a horizontally oriented first panel having an integrated metal channel fixed to the concrete, d) The step of removing the formwork, e) A step of moving the horizontally oriented first panel from a horizontal to a vertical position, wherein the first end face length to which the support coupling for the double gasket assembly is attached is also oriented vertically, f) A step of providing a second panel in a vertical position, wherein the length of the second end face is also oriented vertically, g) Aligning the first and second wall panels such that the first main surface of the first wall panel and the first main surface of the second wall panel are located on the same first plane, the opposing second main surface of the first wall panel and the opposing second main surface of the second wall panel are located on the same second plane, and the first and second planes form a pair of parallel main planes, The first end face of the first wall panel and the second end face of the second wall panel also form a pair of parallel end face planes. The support coupling of the double gasket assembly, which is attached to the first end face, is positioned between the first end face of the first wall panel and the second end face of the second wall panel, within both a pair of parallel main planes and a pair of parallel end planes. The steps include: moving the second wall panel relative to the first wall panel so that the second end face is moved to a desired distance close to the first end face, thereby forming a desired width for the joint between the end faces; h) A step of attaching the support coupling for the double gasket assembly to the metal channel, The support coupling comprises a base, and the base has an upper surface and a bottom surface. The upper surface further includes an inner gasket support and an outer gasket support. The bottom surface of the base has a contact area for stabilizing the support coupling on the end surface, and the bottom surface further has a mounting area for attaching the support coupling to the metal channel, and the mounting area is at least one protrusion. The steps include: either before or after attaching the support coupling to the metal channel, a compressed inner gasket is attached to the inner gasket support of the support coupling, and a compressed outer weather gasket is attached to the outer gasket support of the support coupling; i) The step of expanding the compressed inner gasket and the compressed outer weather gasket, or enabling them to expand, so as to contact and compress them against both the first end face of the first panel and the second end face of the second panel, thereby sealing the joint between the end faces of the two panels, process.

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