Wall panel module containing a double gasket assembly

Abstract

1. A wall panel module comprising a first wall panel and one or more double gasket assemblies, the double gasket assemblies adapted to seal a joint between end faces of two wall panels, the double gasket assemblies comprising a support coupling, a compressible inner gasket and a compressible weather gasket, the support coupling comprising a base having a top surface with inner gasket supports and outer gasket supports at opposite ends of the support coupling, the compressible inner gasket attached to the inner gasket support and the compressible outer weather gasket attached to the outer gasket support, the compressible inner gasket and the compressible outer weather gasket attached to the support coupling, wherein lengths of the compressible inner gasket and the compressible outer weather gasket are parallel to each other and to a length of the double gasket assembly, the bottom surface of the base of the support coupling further comprising an attachment area, the double gasket assembly being attached to a first end face of the first wall panel via said attachment area.

Description

[Technical field]

[0001] FIELD OF THEINVENTION. The present invention relates to a wall panel module utilizing a dual gasket assembly suitable for sealing abutment joints between panels in commercial and other construction. The present invention may be particularly useful in prefabricated wall panels and wall assemblies in that joint sealing features may be pre-installed in individual wall panels before the panels are assembled into a wall. As used herein, "panel" and "wall panel" are used interchangeably. [Background technology]

[0002] Description of Related Art. In some buildings, exterior walls may be non-structural and do not carry any major structural loads other than their own weight. The primary function of these exterior walls is to provide protection from the elements. Such exterior walls may include a series of wall panels connected to a building support structure of columns and floors that carry the majority of the building's structural load. The wall panels are typically designed to resist air and water infiltration, absorb sway induced by wind and seismic forces acting on the building, withstand wind loads, and support their own weight. Individual panels may span multiple floors and vary in length, presenting challenges in sealing the joints between the panels, i.e., sealing the small gaps between the ends of the individual panels in the final wall. These sealed joints must meet design requirements associated with various building codes, as well as other desired performance expectations (e.g., thermal expansion and contraction, building sway and movement, water deflection, and thermal efficiency).

[0003] The gaps between the end faces of individual wall panels, referred to herein interchangeably as "joint joints" or "inter-panel joints," have traditionally been sealed from the outside of the building after the wall panels have been placed in place and attached to the building support structure. In one conventional process, after the panels are installed, the gaps between the panels are first sealed by forcing a resilient support known as a backing rod into the gap from the outside of the building. This backing rod then serves as a support for manual injection of a wet (liquid) sealant from the outside of the building onto the outwardly facing surface of the backing rod. Optionally, the inwardly facing surface of the backing rod can be further manually sealed in a similar manner from the inside of the building with a wet (liquid) sealant if a double seal is desired. The wet sealant fills at least a portion of the gap between the ends of two adjacent panels, and as the sealant cures, provides an essentially permanently fixed air and water seal supported by the backing rod.

[0004] Creating an effective air and water seal requires advanced craftsmanship, sometimes at great heights and in unfavourable weather conditions. The long curing times of wet sealants can also impact construction timelines. All of these sealing operations on the exterior of multi-storey walls after the walls are installed require expensive lifting and scaffolding for workers, and have associated safety concerns.

[0005] Therefore, there is a need for a method of sealing inter-panel joints that does not require extensive work on the outside of the wall to seal these joints after the panels are in place to form the wall. Summary of the Invention [Means for solving the problem]

[0006] The present invention provides a wall panel module including a first wall panel and a double gasket assembly, the first wall panel has a first major surface and an opposite second major surface, the first and second major surfaces lying in a pair of parallel planes; the first wall panel further has a first end surface generally perpendicular to both the first major surface and the opposite second major surface; The double gasket assembly is adapted to seal a joint between end faces of two wall panels, the joint having a length, a width, and a depth, the double gasket assembly including a support coupling, a compressible inner gasket, and a compressible weather gasket; the support coupling includes a base, the base having a top surface and a bottom surface, the top surface further including inner and outer gasket supports at opposite ends of the support coupling; a compressible inner gasket attached to the inner gasket support and a compressible outer weather gasket attached to the outer gasket support, each of the compressible inner gasket and the compressible outer weather gasket having a length, the compressible inner gasket and the compressible outer weather gasket being attached to a support fixture, wherein the lengths of the compressible inner gasket and the compressible outer weather gasket are parallel to one another, and the gaskets are further bounded by a pair of parallel planes; a bottom surface of the base of the support coupling further having an attachment area, the double gasket assembly being attached to the first end surface of the first wall panel via the attachment area; Concerning wall panel modules.

[0007] The present invention also provides a wall panel module including a first wall panel and a plurality of dual gasket assemblies, the first wall panel has a first major surface and an opposite second major surface, the first and second major surfaces lying in a pair of parallel planes; the first wall panel further has a plurality of end faces generally perpendicular to both the first major surface and the opposing second major surface, each end face having an end width that is a thickness of the first panel and an end length that is a length of the end face perpendicular to the end width; Each double gasket assembly is adapted to seal a joint between end faces of two wall panels, the joint having a length, a width, and a depth, and each double gasket assembly includes a support coupling, a compressible inner gasket, and a compressible weather gasket; Each support fitting includes a base, the base having a top surface and a bottom surface, the top surface further including inner and outer gasket supports at opposite ends of the support fitting, the compressible inner gasket being attached to the inner gasket supports and the compressible outer weather gasket being attached to the outer gasket supports of each support fitting; each compressible inner gasket and compressible outer weather gasket having a length, the compressible inner gasket and compressible outer weather gasket being attached to a respective support coupling, wherein the lengths of the compressible inner gasket and the compressible outer weather gasket are parallel to one another, and the gaskets are further bounded by a pair of parallel planes to form a respective dual gasket assembly; a bottom surface of the base of each support coupling further having an attachment area, and each double gasket assembly is attached to the end surface of the first wall panel via said attachment area; Concerning wall panel modules. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a perspective view of an example 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 frontage; [Diagram 3] FIG. 13 is a cross-sectional view of a preferred embodiment of a support fitting for a double gasket assembly further having at least one gutter for directing water. [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, further having at least one gutter for directing water. [Diagram 5] 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. FIG. [Figure 6]FIG. 1 is a perspective view of a building showing an example of multiple panels joined together to form the exterior wall of a building, where the panels are rectangular and the inter-panel joints between the panels are sealed. [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 major faces and four end faces. [Figure 8] FIG. 2 is a perspective view of a panel module including a panel and a dual gasket assembly attached to an edge face of the panel. [Figure 9] FIG. 1 is a perspective view of a panel module including a panel and two double gasket assemblies attached to two end faces of the panel. [Figure 10] FIG. 1 is a diagram of a drainage duct including a body with mounting accessories, a water collection area, a drainage channel, and a compressible gasket with an outer port. [Figure 11] FIG. 13 is a diagram showing the installation and function of a drainage duct combined with a double gasket assembly at the junction of the double gasket assembly, shown cut away and partially assembled. [Figure 12] FIG. 13 is a diagram showing the installation and function of a drainage duct combined with a double gasket assembly at the junction of the double gasket assembly, shown cut away and partially assembled. [Figure 13] FIG. 1 is a partially exploded view showing the joining of two gaskets by a two-way gasket connector. [Figure 14] FIG. 13 is a fully exploded view of joining four gaskets using a four-way gasket connector. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] The present invention relates to sealing features and methods for sealing joints between panels, preferably inter-panel joints, in commercial wall construction, as well as to products that include such sealing features along with features for draining water that may collect in such joints. As used herein, the phrases "joint 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 encompass, but is not limited to, panels used as wall components in buildings. Panels may be panels of inorganic or organic materials, including metal, glass, concrete, wood, and composites. Furthermore, unless otherwise indicated, there is no implied limitation on the orientation, design, or shape of the panels, and while many building walls are generally vertically oriented and rectangular in shape, the invention described herein may be applied to all inter-panel joints of any orientation or type useful in buildings. The invention described herein may further relate to joint sealing features that are pre-attached to individual panels before the panels are assembled into a wall.

[0010] Specifically, the invention disclosed herein relates to double gasket assemblies for sealing one or more joints and their use in panel modules and panelized wall systems, as well as other components used in such panels and panelized walls, and processes for making all of these inventions. In addition, the invention disclosed herein includes features specifically designed to manage and drain water that may unintentionally collect in the double gasket assemblies.

[0011] In some embodiments, these inventions are made at a construction site and then used to construct the walls of a building. In other embodiments, the inventions are prefabricated. By "prefabricated" we mean that the article is manufactured at a manufacturing facility or some other site away from the construction site where the walls will be erected. This may allow economies of scale in the manufacture of the article, and the article may also be stored until it is ready for use, and when needed, the article may be delivered to one or more building sites as needed. Intuitively, the use of prefabricated articles should reduce the time required to build and seal panelized walls at the construction site.

[0012] 6 is a perspective view of a building 62 showing an example of a number of panels 60 (not all of which are labeled) coupled to the supporting structure of the building. In this view, the panels are rectangular with major (exterior) faces having a particular vertical height H and a particular horizontal width W, with inter-panel joints between the panels, represented in this view by inter-panel joint lines 64a, 64b, 64c, 64d.

[0013] The panels 60 are shown arranged in a side-by-side configuration. The panels can be in-line with one another as shown, or can be offset relative to one another (not shown). As depicted in this figure, the panels 60 are typically modular such that they substantially overlap one another. However, a building may include different panels, such as panels having different sizes, shapes, and / or configurations. For example, as shown in FIG. 6, the panels 60 on one side of the building are smaller than the panels 66 (not all labeled) on another side of the building.

[0014] This configuration of panels in a building wall assembly shown in FIG. 6 shows four inter-panel joints 64a, 64b, 64c, 64d around one of the rectangular panels 60. In this configuration, the building wall assembly presents a substantially continuous exterior surface of the building. In other wall assemblies, the panels can be arranged such that only two inter-panel joints need to be sealed. For example, in one type of wall assembly, as shown as the bottom of building 62 in FIG. 6, the individual panels 68 (not all of which are labeled) can be sized and arranged sufficiently such that the inter-panel joints are only vertically oriented joints, e.g., lines 69a and 69b. Conversely, the panels can be sized and arranged such that the inter-panel joints are only horizontally oriented joints. Many combinations are possible, as are the orientations of the joint joints. The panels may span less than one floor, one floor, or more than one floor of the structure. A wall assembly including the wall panels can represent the entire envelope (or exterior facade) of a building, or only a portion of it.

[0015] Double Gasket Assembly A double gasket assembly is used to seal the inter-panel joints. Figure 1 is a perspective view of an example of a double gasket assembly 10 including a support fitting 11, a compressible inner gasket 12, and a compressible outer weather gasket 14. The double gasket assembly further includes at least one gutter for directing water, which in this illustration includes an optional series of holes 15 for attaching the support fitting to the end face.

[0016] The double gasket assembly is suitable for sealing a joint 20 between the edges of two panels, as shown in FIG. 2, the joint having a length, a width, and a frontage. 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 edges, the edges being perpendicular to the major faces of the panels. The joint length 23 is the length of the larger sealable edge dimension measured parallel to the plane of the panels. The joint width 24 is the smaller sealable edge dimension measured perpendicular to both the joint length 23 and perpendicular to the plane of the panels. The joint width is essentially the thickness of the panels, assuming that the joint is between two panels of equal thickness. If the two panels are of different thickness, the joint width is the thickness of the thinner panel. Joint frontage 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, joint frontage 25 (the gap between the edges when the panel is installed in a wall) can be, and typically is, much smaller than joint width 24 (which is typically the width of the panel). For example, joint width 24 may be 4 to 8 inches, while joint frontage 25 may be 1 / 2 to 1 inch.

[0017] Similarly, as shown in FIG. 1, the double gasket assembly has a generally elongated rectangular footprint on an edge of a wall panel and is configured to be attached to the edge of a wall panel, and therefore has a length 16, width 17, and frontage 18 measured in a manner similar to the joint length 23, width 24, and frontage 25 of the joint. Specifically, the length 16 of the double gasket assembly 10 is the overall centerline length of the linear 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 of the joint being sealed. The length 16 of the double gasket assembly, or a portion of the double gasket assembly, can be greater than, equal to, or less 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 the same as or shorter than the joint length 23. For example, it may be desirable to have the ends of two adjacent horizontally oriented compressible outer weather gaskets sealing two horizontal joints between two sets of adjacent panels meet at a vertical joint between the two sets of panels. Thus, each of the compressible outer weather gaskets may be slightly longer than the horizontal joints they seal, with the actual length being determined by the width of the gasket connector used to connect the two gasket ends.

[0018] 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 and parallel to the joint width 24. In some embodiments, the joint width 24 is substantially greater than the double gasket assembly width 17, and in some embodiments, the double gasket assembly width 17 is 50% or less of the joint width 24. In some embodiments, the double gasket assembly width 17 is 25% or less of the joint width 24.

[0019] The frontage 18 of the double gasket assembly is the thickness of the double gasket assembly. It 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. As used herein, the term "original frontage" of the double gasket assembly is the frontage of the double gasket assembly prior to compression of the gaskets. The double gasket assembly preferably has an original frontage 18 that is greater than the frontage 25 of the joint between the two wall panels.

[0020] 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 includes an elongate body having a base 31, the base having a top surface 32 and a bottom surface 33, the top surface of the base having at least one gutter 34 for conducting water. In this embodiment, the gutter is formed between two weirs 35 on the top surface of the support coupling. The top surface of the base further includes an inner gasket support 36 and an outer gasket support 37, the inner gasket support and the outer gasket support being separated by at least one gutter 34 for conducting water. A compressible inner gasket is attached to the inner gasket support and a compressible outer weather gasket is attached to the outer gasket support (no gaskets are attached in FIG. 3). In the embodiment of Figure 3, both the inner gasket support 36 and the outer gasket support 37 have C-shaped gasket retaining cavities that are C-shaped channels that run the length of and are parallel to the support fittings of the dual gasket assembly designed for use with a compressible inner gasket and a compressible outer weather gasket, each gasket having a matching T-shaped protrusion. In some embodiments, the support fittings have a length parallel to the length of the dual gasket assembly that corresponds to the length of the joint between the end faces of the two wall panels to be sealed.

[0021] The bottom surface 33 of the base 31 of the support fitting 30 has a contact area 38 for stabilizing the support fitting to an end surface of one of the two wall panels. The bottom surface further has an attachment area for attaching the support fitting to the end surface, the attachment area being at least one surface, protrusion, or cavity.

[0022] In the embodiment shown in Figure 3, the entire bottom surface of the base is the contact area 38, with many different attachment area options available. For example, the support coupling can be attached to the end surface by applying an adhesive strip or adhesive foam to the bottom surface 33 of the base of the support coupling at the attachment area, which can be part or all of the contact area 38 of the support coupling if sufficient for the application. Optionally, the contact area of ​​the base of the support coupling can have a set of holes 15 (Figure 1) extending from the top surface 32 to the bottom surface 33 for use with a set of fasteners (e.g., screws, nails, etc.) to secure the contact area to the edge surface of the panel, the holes being the attachment area.

[0023] Optional support fitting feature 39 is also shown in FIG. 3, which can thicken the base in the gutter as shown in dotted lines to further reinforce the support fitting. Additionally, if desired, a V-notch can be provided in that area that runs the length of the support fitting. The V-notch can be used when using self-drilling screw fasteners (such as self-tapping screws) to attach the support fitting to an end face when no pre-drilled holes are present to prevent the self-drilling screw fasteners from "moving."

[0024] 4 is a cross-sectional view of a preferred dual gasket assembly 40 including a support fitting 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 flattened hourglass shape with the flattened or straight sides (contact faces) of the hourglass configured to mate with the flat end faces of the panels to be sealed. The compressible inner gasket and the compressible outer weather gasket are attached to the support fitting via gasket supports (45 and 46) at opposite ends of the support fitting, and the inner gasket support 45 and the outer gasket support 46 are separated by at least one gutter 44 for directing water.

[0025] The attachment of a compressible inner gasket and a compressible outer weather gasket on either side of at least one gutter provides the advantage of a redundant gasket system that further allows for a mechanism to collect and drain liquid water that may break through the compressible outer weather gasket or condense between the gaskets, with the compressible outer weather gasket generally facing the exterior environment of the wall and the compressible inner gasket generally facing the interior environment of the wall.

[0026] In the embodiment shown in Figure 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 projection 47 that seats in each C-shaped cavity. Figure 4 also shows an optional set of holes 49 through the base of the support coupling for use with a set of fasteners (e.g., screws, nails, etc.) to secure the contact areas to the end faces of the panels. In some embodiments, the dual gasket assembly has a length that corresponds to the length of the joint between two wall panels.

[0027] FIG. 4 further illustrates the width and frontage dimensions of the double gasket assembly, both of which can be measured perpendicular to the length of the double gasket assembly. The width of the double gasket assembly is dimension 400 in FIG. 4, i.e., the dimension parallel to the width dimension of the joint to be sealed, and the compressible inner gasket 42, the support coupling 41, and the compressible outer weather gasket 43 all contribute 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 frontage of the double gasket assembly is also shown in FIG. 4, i.e., the original frontage of the double gasket assembly with the gaskets in a non-compressed state. In some embodiments, the double gasket assembly has a width measured perpendicular to both the length and frontage of the double gasket assembly, and the width is 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 joint between two wall panels.

[0028] The original frontage of a double gasket assembly is the thickness of the double gasket assembly before the gaskets are compressed in sealing the joint joints. The original frontage is the distance between the outermost portion of each gasket that contacts the edge of the panel and is shown as dimension 401 in FIG. 4. In this figure, the flat edge shown on the compressible inner gasket and the flat edge shown on the compressible outer gasket are the outermost portions from which the original frontage is measured. For purposes herein, the frontage of a double gasket assembly is measured without the projections extending from the base and only the measurements of the gaskets are considered. Additionally, although the figures show gaskets with flat faces, other shapes are possible, in which case the original frontage of a double gasket assembly is the maximum thickness of the uncompressed gaskets measured perpendicular to the base of the supporting joint.

[0029] To form a seal, the double gasket assembly has an original frontage that exceeds the frontage of the joint between the two panels being sealed. Once the double gasket assembly seals the joint between the two panels, the installed frontage of the double gasket assembly is preferably the same as the frontage of the joint between the two panels.

[0030] 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 may also be integral with its associated gasket. However, in some embodiments, it may be desirable to have only the compressible inner gasket integral with the gasket support, and to leave the compressible outer weather gasket removable from the support so that it can be replaced if necessary due to weathering.

[0031] 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 a respective gasket, where each gasket has a matching cavity for seating an associated gasket retaining projection.

[0032] Specifically, in some embodiments, the compressible inner gasket of the dual gasket assembly is attached to the inner gasket support by either: i) a protrusion extending from the inner gasket support that seats in a cavity within the compressible inner gasket; or ii) A projection extending from the compressible inner gasket which seats in a cavity in the inner gasket support.

[0033] In some embodiments, the compressible outer weather gasket of the dual gasket assembly is attached to the outer gasket support by: i) a projection extending from the outer gasket support that seats in a cavity of the compressible outer weather gasket; or ii) A projection extending from a compressible outer weather gasket which seats in a cavity in the outer gasket support.

[0034] In some preferred embodiments, the inner gasket support and the outer gasket support each have at least one projection or cavity for mounting the gasket. As used herein, a "projection" extending from a part means that the part has an appendage extending (or protruding) from the part and 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 to each other. In some embodiments, the projection is known as a "dart" and can have any shape typically used for darts as 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 the part.

[0035] "Seat" or "seated" means that a projection is mechanically held or maintained within a cavity to secure the projection to the cavity and connect or attach two parts to each other. Cavity means a pocket, groove, unfilled space, or hollow space in the surface of a part having a suitable size and shape that can receive and seat a projection of suitable size and shape.

[0036] If projections and cavities are used, they must properly attach each gasket and gasket support to one another so that the dual gasket assembly can be further attached to the end face of the panel, the gaskets will remain attached if the panel moves, and the gaskets can be compressed between two adjacent end faces without either gasket coming off its gasket support. Alternatively, a support fitting can be first attached to the end face of the panel, and then each gasket can be attached with any combination of projections and cavities, which must again properly attach each gasket and gasket support to one another so that the gaskets will remain attached if the panel moves, and the gaskets can be compressed between two adjacent end faces without either gasket coming off its gasket support.

[0037] Many different configurations of projections and cavities are possible. For example, a linearly arranged set of individually isolated gasket darts and a compatible linearly arranged set of individually isolated gasket support cavities may be used, both linear arrangements oriented parallel to the gutter when installed and extending substantially the length of the support fitting, with the number of attachment points being determined by the application of the gasket. In a preferred embodiment, the projections are continuous projections, meaning that they extend substantially the length of the support fitting oriented parallel to the gutter when installed. Similarly, in a preferred embodiment, the cavities are continuous channels, again meaning that they extend substantially the length of the support fitting oriented parallel to the gutter when installed.

[0038] In some preferred embodiments, the projection may have a cross-sectional "T" shape that may seat within a cavity having a cross-sectional "C" shape, as illustrated by the cross-sectional views of the support fitting and dual gasket assembly in Figures 3 and 4. The C-shaped cavity typically forms a channel on or within the support fitting base, which is oriented parallel to the trough and preferably extends continuously along the length of the support fitting base. Similarly, the associated gasket has a T-shaped projection that preferably extends continuously along the length of the gasket.

[0039] In some preferred embodiments, the compressible inner gasket and the compressible outer weather gasket have the same shape, one preferred shape is shown in FIG. 4 as a hollow flat hourglass shape with two bulges, the flat or straight side of the hourglass configured to mate with the flat edge of the panel to be sealed. However, the shapes of the compressible inner gasket and the compressible outer weather gasket do not have to be the same. It is contemplated that other gasket shapes and materials are suitable for use in this application. 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, can be used as the gaskets of the dual gasket assembly.

[0040] In a preferred embodiment, the gaskets and gasket supports are configured such that when the dual gasket assembly is first or simply attached to the end face of a wall panel, both the compressible inner gasket and the compressible outer weather gasket are not compressed against the end face of the wall panel. 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 on the end face of the wall panel because it eliminates the need to partially compress the gaskets when first installed on the first panel end face.

[0041] For example, in the preferred embodiment shown in Figure 4, the dual gasket assembly may be attached to an end face of a wall panel by first attaching the support fitting to the end face and then attaching the compressible inner gasket by sliding the T-shaped projection of the compressible inner gasket onto the C-shaped inner gasket support of the support fitting. The compressible outer weather gasket may be similarly attached to the outer gasket support. Because the bottom surface of the gasket is at most flush with the bottom surface of the support fitting, the gasket may be slid into the C-shaped cavity of the support fitting without substantial friction from the end face of the wall.

[0042] Alternatively, both the compressible inner gasket and the compressible outer weather gasket can be attached to the support fitting, again by sliding each T-shaped gasket projection onto the associated C-shaped gasket support on the support fitting to create a fully assembled dual gasket assembly, which can then be attached to the end face of the wall panel. Again, the bottom face of the gasket is at most flush with the bottom face of the support fitting, so the dual gasket assembly can be attached without first compressing the gasket to the end face of the wall panel. Either of these methods allows for easier and more accurate placement of the dual gasket assembly on the end face of the wall panel. Additionally, this preferred gasket configuration still provides for proper sealing of the joint because both the compressible inner gasket and the compressible outer weather gasket are subsequently compressed against both end faces of the joint by contacting the second end face of another wall to completely seal the joint.

[0043] The compressible inner gasket and the compressible outer weather gasket can comprise any resilient material fabricated into a compressible shape that can provide an adequate seal and that has suitable durability to withstand the rigors of construction. Certain panel applications may have additional preferred requirements for the gasket material, such as thermal expansion and contraction characteristics within certain ranges, and remaining flexible over time and with temperature changes to accommodate building sway and movement. The compressible outer weather gasket preferably also has adequate weather resistance, such as not being overly affected by water and / or ultraviolet light.

[0044] Resilient materials contemplated as suitable for use in the compressible inner gasket and 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 and other flexible polyurethanes and polyethylenes, etc. The compressible forms of the gaskets may include open center and relatively hollow or hollow expanded structures as shown in the present illustration, or various types of closed cell foams.

[0045] Because the compressible inner gasket and compressible outer weather gasket in the dual gasket assembly are significantly compressed at the sealed joint, an open center, relatively hollow, or hollow expansion gasket construction is preferred in many embodiments. Specifically, the gaskets in the dual gasket assembly are preferably capable of durable compression such that the frontage of the dual gasket assembly in a compressed state at the sealed joint is at least 80% of its original frontage, preferably at least 75% of its original frontage, and most preferably at least 50% of its original frontage at the sealed joint.

[0046] The bottom surface of the base of the support fitting of the dual gasket assembly has a contact area for stabilizing the support fitting on the edge surface of the panel. The bottom surface of the base further has an attachment area for attaching the support fitting to the edge surface, the attachment area being at least one surface, protrusion, or cavity.

[0047] The attachment area being "at least one surface" is intended to apply to support couplings that require additional fasteners or adhesives to attach a portion of the support coupling's contact area to the edge surface of the panel. Examples of such couplings are shown in Figures 3 and 4, where the attachment area is a surface, i.e., a portion of the support coupling's bottom surface 33, which in these figures is also a portion of the support coupling contact area 38.

[0048] In many embodiments, the contact area for stabilizing the support coupling on an end surface is larger than the attachment area for attaching the support coupling on the end surface. This is especially true when the support coupling is attached on the end surface using an attachment area that is a protrusion or a cavity. FIG. 5 is a cross-sectional view of an embodiment of the bottom surface of the base of a support coupling where the attachment area is at least one protrusion. The support coupling 50 has a gutter 55 formed by two weirs 57 and also has two gasket supports 59 with darts. The gasket supports also form two other optional channels 56 that may also be used for drainage. 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 surface 53 of the panel (the dotted line indicates the location of the end surface of the panel). This attachment area is considered to be the area on the bottom surface of the base in the plane of the bottom surface of the base for attaching the support coupling to the end surface.

[0049] The projection 52 shown in Figure 5 has a chamfered "T" shape designed to slide or fit into a C-shaped channel (or cavity) in the panel edge face 53. Additionally, Figure 5 illustrates a support fitting in which the base attachment area 51 is not the same as the contact area 54 that stabilizes the support fitting on the panel edge face.

[0050] Alternatively, the support fitting may have an attachment area which is a cavity in the support fitting base suitable for attaching the support fitting to an end face of the panel via a fitting retention protrusion on the wall panel. In this embodiment, the fitting retention protrusion extends from the end face of the panel and the base attachment area of ​​the support fitting is considered to be the area of ​​the entrance opening to the cavity in the support fitting base in the plane of the bottom surface of the base.

[0051] In some embodiments, the dual gasket assembly is adapted to seal a joint between a first surface area of ​​a first end face of a first panel and a second surface area of ​​a second end face of a second panel. In the first panel, the first surface area to be sealed is a generally rectangular area on the first end face, having a major axis with a first surface length and a minor axis with a first surface width, and in the second panel, the second surface area to be sealed is also a generally rectangular area on the second end face, having a major axis with a second surface length and a minor axis with a second surface width. In some embodiments, at least one gutter for conducting water has a length corresponding to the first surface length of the first surface area.

[0052] 7 is a perspective view of a panel 71 having a rectilinear shape, the panel having six sides. The six sides include two major faces and four end faces. Shown is a first major face 72, which is the front side of the panel, and an opposite second major face 73, which is the back side of the panel. When the panel is used in a building structure, typically the first major face 72 (or front) is the side of the panel that is exposed to weather or closest to the exterior of the building and faces outward, while the opposite second major face 73 (or back) is the side of the panel that is the interior wall of the building or closest to the interior of the building and faces inward.

[0053] The dual gasket assembly is used to seal the joint 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 against a second surface area of ​​the second end face of the second panel. FIG. 7 shows a first surface area on a first panel to be sealed, which is the shaded area of ​​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 of ​​that end face and the minor axis being the shorter dimension of the surface area of ​​that same end face. Similarly, although not shown, a second surface area on a second end face of a second panel to be sealed similarly has a second major axis having a second surface length and a second minor axis having a second surface width, the major axis being the longer dimension of the surface area of ​​that end face and the minor axis being the shorter dimension of the surface area of ​​that same end face.

[0054] Ultimately, the gap between the 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 dual gasket assembly. For purposes of clarity, however, the features of the first panel will be considered first.

[0055] 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 is perpendicular or generally 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.

[0056] The use of the phrase "surface area to be sealed" refers to the surface area on the end faces of the panels that will be at least partially contacted by the double gasket assembly after the gasket assembly is fully installed between the end faces of the two panels, thereby sealing the abutment gap. It is not necessary for the double gasket assembly to be in contact with the entire width of the end faces in order to seal the joint. In many cases, the width of the double gasket assembly will not be as wide as the thickness of the panel, and it is generally desirable to place the double gasket assembly near the exterior surface (major surface 72) of the panel and the wall, rather than near the interior surface (major surface 73) of the panel and the wall, to seal the area shown by the cross-hatched area in FIG. 7. In some embodiments, it is desirable to place the double gasket assembly flush with the exterior surface (major surface 72) of the panel, giving the wall the appearance of an essentially continuous surface. In other embodiments, it is desirable to place the double gasket assembly not flush with the exterior surface of the panel, but recessed inwardly between the panels from the exterior surface of the wall, which will provide a wall surface with more clearly defined panels and joints when an aesthetic appearance is desired.

[0057] The first surface area 75 to be sealed further has a first surface length, represented by the distance between points AD or EF, if the surface is generally rectangular, and a first surface width, represented by the distance between points AE or DF, also if 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 surface (major surface 72) of the panel than to the back surface (major surface 73) of the panel. However, the first surface width AE or DF of the surface area 75 can be the same width as the first edge 74, or the first surface width AE or DF can be located at any point within the width of the first edge 74.

[0058] In a typical linear wall construction, a first major surface 72 of a first panel lies in an exterior surface extending in all directions from that panel, and the first major surfaces of multiple other such panels form the exterior wall surface, while an opposing second major surface 73 of the first panel lies in an interior surface extending in all directions from that panel, and the second major surfaces of multiple other such panels form the interior wall surface.

[0059] Wall Panel Module The present invention also relates to a wall panel module including a first wall panel and a double gasket assembly attached thereto. The first wall panel has a first major surface and an opposite second major surface, the first and second major surfaces lying in a set of parallel planes, and the first wall panel further has a first end surface that is generally perpendicular to both the first major surface and the opposite second major surface. In some preferred embodiments, the panel has a rectilinear shape, and the panel has six sides encompassing two major surfaces and four end surfaces.

[0060] The dual gasket assembly attached to the wall panel is adapted to seal a joint between end faces of two wall panels, the joint having a length, a width, and a depth. The dual gasket assembly includes a support fitting, a compressible inner gasket, and a compressible outer weather gasket. The support fitting of the dual gasket assembly includes a base, the base having a top surface and a bottom surface, the top surface of the base optionally, but preferably, having at least one gutter channel for directing water. The top surface further includes an inner gasket support and an outer gasket support, the inner gasket support and the outer gasket support being at opposite ends of the base, and when at least one gutter channel is present, the inner gasket support and the outer gasket support are separated by the at least one gutter channel.

[0061] The compressible inner gasket is attached to the inner gasket support and the compressible outer weather gasket is attached to the outer gasket support of each support fitting, each compressible inner gasket and compressible outer weather gasket having a length that is a gasket length parallel to the length of the double gasket assembly. Furthermore, the compressible inner gasket and the compressible outer weather gasket are attached to the support fitting with the lengths of the compressible inner gasket and the compressible outer weather gasket parallel to each other and also parallel to the length of the double gasket assembly, both gaskets being further bounded by a set of parallel planes extending from the first major surface and the second major surface of the first wall panel to form each double gasket assembly. The bottom surface of each support fitting base further has an attachment area, and each double gasket assembly is attached to an end face of the first wall panel via the attachment area.

[0062] Figure 8 is a view of a wall panel module 80 including a panel 81 and a single double gasket assembly 82 attached to an end face 83 of the panel. Figure 8, like Figure 7, illustrates that the double gasket assembly does not need to contact the entire width of the end face to seal the joint. As shown in Figure 8, the width of the double gasket assembly is not as wide as the width of the end face (the thickness of the panel), and the double gasket assembly is placed near the opposite exterior surface 84 of the panel rather than near the interior surface of the panel, sealing an area similar to the shaded area designated by corner point AEFD in Figure 7.

[0063] In some embodiments, the wall panel module has a double gasket assembly having an attachment area that includes at least one surface, protrusion, or cavity. In some embodiments, the wall panel module has a double gasket assembly, wherein the inner gasket support and the compressible inner gasket of the double gasket assembly are integral.

[0064] In some embodiments, the wall panel module has a dual gasket assembly, with the compressible inner gasket attached to the inner gasket support by either: i) a projection extending from an inner gasket support seated in a cavity within the compressible inner gasket; or ii) A projection extending from a compressible inner gasket seated in a cavity in the inner gasket support.

[0065] In some embodiments, the wall panel module has a dual gasket assembly, where the compressible outer weather gasket is attached to the outer gasket support by: i) a projection extending from the outer gasket support that seats in a cavity of the compressible outer weather gasket; or ii) A projection extending from a compressible outer weather gasket which seats in a cavity in the outer gasket support.

[0066] In some embodiments, the wall panel module has a double gasket assembly with a support fitting, the contact area for stabilizing the support fitting of the double gasket assembly on the panel end face being greater than the attachment area for attaching the support fitting to said end face.

[0067] In some embodiments, the wall panel module has a double gasket assembly having a length corresponding to the length of the joint to be sealed between two wall panels.

[0068] In some embodiments, the wall panel module has a double gasket assembly with a support coupling having a length corresponding to the length of the joint between two wall panels.

[0069] In some embodiments, the wall panel module has a double gasket assembly that has a width that is less than the width of the joint joint between two wall panels.

[0070] Although not repeated herein for the sake of brevity, any of the features, options, and elements described herein with respect to the double gasket assembly or any of its components apply equally to a wall panel module that includes a double gasket assembly.

[0071] Wall panel module including a plurality of double gasket assemblies In some embodiments, the wall panel module may include a first wall panel and a plurality of double gasket assemblies attached thereto, the first wall panel having a first major surface and an opposing second major surface, the first and second major surfaces lying in a set of parallel planes. The first wall panel further has a plurality of end surfaces generally perpendicular to both the first major surface and the opposing second major surface, each end surface having an end width that is the thickness of the first panel and an end length that is the length of the end surface perpendicular to the end width. Each of the double gasket assemblies attached to the first wall panel is adapted to seal a joint between the end surface or the first wall panel and another wall panel, the joint having a length, width, and depth determined by the dimensions of the individual wall panels to be sealed. As previously described herein, each dual gasket assembly includes a support coupling, a compressible inner gasket, and a compressible outer weather gasket, each support coupling including a base, the base having a top surface and a bottom surface, the top surface further including an inner gasket support portion and an outer gasket support portion on opposite ends of the support coupling. Preferably, the top surface of each base of the support coupling further includes at least one gutter for conducting water, the inner gasket support portion and the outer gasket support portion being separated by the at least one gutter.

[0072] The compressible inner gasket is attached to the inner gasket support and the compressible outer gasket is attached to the outer gasket support of each support fitting, each compressible inner gasket and compressible outer gasket having a length that is a gasket length parallel to the length of the double gasket assembly. Furthermore, the compressible inner gasket and the compressible outer weather gasket are attached to the support fitting with the lengths of the compressible inner gasket and the compressible outer weather gasket parallel to each other and also parallel to the length of the double gasket assembly, both gaskets being further bounded by a set of parallel planes extending from the first major surface and the second major surface of the first wall panel to form each double gasket assembly. The bottom surface of each support fitting base further has an attachment area, and each double gasket assembly is attached to an end surface of the first wall panel via said attachment area.

[0073] Although not repeated herein for the sake of brevity, any of the features, options, and elements described herein with respect to a double gasket assembly or a wall panel module including a double gasket assembly, or any of its components, apply equally to a wall panel module including multiple double gasket assemblies.

[0074] The building 62 shown in FIG. 6 includes a plurality of panels 60 with a plurality of inter-panel joints shown, one between each pair of panels. Representative joints in this figure are inter-panel joints 64a, 64b, 64c, and 64d shown around one perimeter of the rectangular panel 60. 64a and 64c represent vertically oriented inter-panel joints, while 64b and 64d represent horizontally oriented inter-panel joints. In some wall constructions, modular units that can be used interchangeably are desired, and a wall panel module including a wall panel and one or more double gasket assemblies attached thereto can provide such a modular unit. Many such types of modular wall panel modules are possible. For example, a wall panel module can include a rectangular panel with a double gasket assembly attached to each of the four end faces, with the wall panel module including a total of four double gasket assemblies. However, a more practical wall panel module (especially for a building 62 as shown in FIG. 6 and considering the desire for interchangeable panel modules) is a wall panel module having two double gasket assemblies attached to a wall panel. Because many wall panels are rectangular with one side longer than the other, a wall panel module including a single horizontally attached double gasket assembly and a single vertically attached double gasket assembly (each attached to an edge perpendicular to each other) can provide a useful interchangeable modular wall panel. For example, FIG. 9 shows a view of a wall panel module 90 including a panel 91 and two double gasket assemblies 92 attached to two edges of the panel, specifically the vertical and horizontal edges of the panel. FIG. 9, like FIGS. 7 and 8, illustrates that the double gasket assemblies do not need to contact the full width of the edges to seal the joints. As in FIG. 8, the width of each of the double gasket assemblies is not as wide as the width of each end face (the thickness of the panel), and each double gasket assembly is positioned near the opposite exterior surface of the panel rather than near the interior surface of the panel, sealing an area similar to the shaded area designated by corner point AEFD in FIG. 7.

[0075] Wall Panel Module Manufacturing Process The present invention also relates to a process for manufacturing a wall panel module including a wall panel and a double gasket assembly, the process comprising the steps of: a) forming a first double gasket assembly including a compressible inner gasket, a support tie, and a compressible outer weather gasket, each of the compressible inner gasket and the compressible outer weather gasket having a length that is a gasket length parallel to a length of the double gasket assembly, the compressible inner gasket and the compressible outer weather gasket being attached to the support tie with the lengths of the compressible inner gasket and the compressible outer weather gasket parallel to one another; b) providing a first wall panel having a first major surface and an opposite second major surface, the first and second major surfaces lying in a set of parallel planes, the first wall panel further having a first end surface that is generally perpendicular to both the first major surface and the opposite second major surface, the first end surface having an end length that is a height of the first panel and an end width that is a thickness of the first panel; c) positioning a first dual gasket assembly adjacent a first end face of the first panel in an area bounded by a set of parallel planes, the lengths of the compressible inner gasket and the compressible outer weather gasket being parallel to the end face length, both gaskets being further bounded by a set of parallel planes; and d) attaching a support coupling of the first double gasket assembly to a first end surface of the first wall panel to form a wall panel module.

[0076] In some embodiments of this process, the support fitting of the dual gasket assembly includes a base, the base having a top and a bottom surface, the top surface further having inner and outer gasket supports at opposite ends of the support fitting, the compressible inner gasket is attached to the inner gasket support and the compressible outer weather gasket is attached to the outer gasket support, and the bottom surface of the base of the support fitting further includes an attachment area for attaching the support fitting to the first end surface of the first wall panel.

[0077] In some embodiments of this process, the top surface of the base of the support fitting further includes at least one gutter for directing water, and the inner gasket support and the outer gasket support are separated by said at least one gutter. Further, the support fitting of the dual gasket assembly can be attached to the first end surface of the first wall panel by an attachment region of the dual gasket assembly.

[0078] If desired, the compressible inner gasket can be integrated with the inner gasket support of the dual gasket assembly in this process. Alternatively, the compressible inner gasket can be attached to the inner gasket support by either: i) a projection extending from the inner gasket support that seats in a cavity of the compressible inner gasket; or ii) A projection extending from the compressible inner gasket which seats in a cavity in the inner gasket support.

[0079] The compressible outer weather gasket in this process can be attached to the outer gasket support by: i) a projection extending from the outer gasket support that seats in a cavity of the compressible outer weather gasket; or ii) A projection extending from a compressible outer weather gasket which seats in a cavity in the outer gasket support.

[0080] In some embodiments of this process, a contact area for stabilizing the support fitting on the end face is greater than an attachment area for attaching the support fitting to the end face. Further, in this process, the support fitting of the dual gasket assembly can have a length corresponding to an end face length of the first end face, and the dual gasket assembly can have a width smaller than an end face width length of the first end face.

[0081] Although not repeated herein for the sake of brevity, any of the features, options, and elements described herein for a double gasket assembly, or a wall panel module including a double gasket assembly, or a wall panel module including a plurality of double gasket assemblies, or any of these components, apply equally to a process for manufacturing a wall panel module including a double gasket assembly.

[0082] In some embodiments, the process can further be used to manufacture a wall panel module including a plurality of double gasket assemblies. Specifically, in some embodiments, the present invention relates to a process for manufacturing a wall panel module including a wall panel and a plurality of double gasket assemblies, the process comprising the steps of: a) forming a plurality of dual gasket assemblies, each dual gasket assembly including a compressible inner gasket, a support tie, and a compressible outer weather gasket, each of the compressible inner gasket and the compressible outer weather gasket having a length that is a gasket length parallel to a length of the dual gasket assembly, the compressible inner gasket and the compressible outer weather gasket being attached to the support tie with the lengths of the compressible inner gasket and the compressible outer weather gasket parallel to one another; b) providing a first wall panel having a first major surface and an opposite second major surface, the first major surface and the second major surface lying in a set of parallel planes, the first wall panel further having a plurality of edge surfaces that are generally perpendicular to both the first major surface and the opposite second major surface, each edge surface having an edge length that is either the vertical length or the horizontal length of the first panel, and an edge width that is a thickness of the first panel; c) positioning each dual gasket assembly adjacent one of the end faces of the first panel in an area bounded by a set of parallel planes, the lengths of the compressible inner gasket and the compressible outer weather gasket being parallel to the end face length, both gaskets being further bounded by a set of parallel planes; and d) attaching a support coupling of each double gasket assembly to said end face to form a wall panel module.

[0083] Although not repeated herein for the sake of brevity, any of the features, options, and elements described herein with respect to any of the components or steps used in the process for manufacturing a wall panel including a double gasket assembly may be equally applicable to a process for manufacturing a wall panel including multiple double gasket assemblies.

[0084] Another embodiment of a process for manufacturing a wall panel module including a wall panel and a double gasket assembly includes the following steps: a) providing a first wall panel having a first major surface and an opposite second major surface, the first and second major surfaces lying in a set of parallel planes, the first wall panel further having a first end surface that is generally perpendicular to both the first major surface and the opposite second major surface, the first end surface having an end length that is a height of the first panel and an end width that is a thickness of the first panel; b) providing a support fitting for the double gasket assembly, the support fitting having a length that is parallel to a length of the double gasket assembly, the support fitting including a base, the base having a top and a bottom surface, the top surface further having inner and outer gasket supports on opposite ends of the support fitting, the bottom surface of the support fitting base further including an attachment area for attaching the support fitting to a first end surface of a first wall panel; c) attaching a support fitting of the first double gasket assembly to a first end surface of the first wall panel, the length of the support fitting being parallel to an end length of the first end surface; and d) attaching a compressible inner gasket to the inner gasket support and a compressible outer weather gasket to the outer gasket support, wherein the lengths of the compressible inner gasket and the compressible outer weather gasket are parallel to the end face lengths, and both gaskets are further bounded by said set of parallel planes.

[0085] In this process, the upper surface of the base of the support coupling can further include at least one gutter for directing water, and the inner gasket support and the outer gasket support are separated by the at least one gutter. Further, in this process, the support coupling can be attached to the first end surface of the first wall panel by the attachment region.

[0086] In this process, the compressible inner gasket can be attached to the inner gasket support by either: i) a projection extending from the inner gasket support that seats in a cavity of the compressible inner gasket; or ii) A projection extending from the compressible inner gasket which seats in a cavity in the inner gasket support.

[0087] Similarly, in this process, the compressible outer weather gasket can be attached to the outer gasket support by: i) a projection extending from the outer gasket support that seats in a cavity of the compressible outer weather gasket; or ii) A projection extending from a compressible outer weather gasket which seats in a cavity in the outer gasket support.

[0088] In this process, the contact area for stabilizing the support fastener on the end face can be larger than the attachment area for attaching the support fastener to the end face. Furthermore, in this process, the support fastener of the double gasket assembly can have a length corresponding to the end face length of the first end face, and after assembly, the double gasket assembly can have a width smaller than the end face width length of the first end face. Any other features or elements described herein for the double gasket assembly, wall panel, or wall panel module can be used in the process for manufacturing the panel module.

[0089] In another embodiment, the process can be used to manufacture a wall panel module including a plurality of double gasket assemblies. Specifically, in some embodiments, the present invention relates to a process for manufacturing a wall panel module including a wall panel and a plurality of double gasket assemblies, the process comprising the steps of: a) providing a first wall panel having a first major surface and an opposite second major surface, the first major surface and the second major surface lying in a set of parallel planes, the first wall panel further having a plurality of edge surfaces that are generally perpendicular to both the first major surface and the opposite second major surface, each edge surface having an edge length that is either a vertical length or a horizontal length of the first panel, and an edge width that is a thickness of the first panel; b) providing a plurality of dual gasket assembly support fittings, each support fitting having a length, the support fitting including a base, the base having a top and a bottom surface, the top surface further including inner and outer gasket supports on opposite ends of the support fitting, the bottom surface of the support fitting base further including an attachment area for attaching the support fitting to one of the end surfaces of the first wall panel; c) attaching each support tie to one of the end faces of the first wall panel, the length of the support tie being parallel to the end length of the end face; and d) on each support fitting, attaching a compressible inner gasket to an inner gasket support and a compressible outer weather gasket to an outer gasket support, the lengths of the compressible inner gasket and the compressible outer weather gasket being parallel to the length of the end face, both gaskets further forming a dual gasket assembly bounded by said set of parallel planes and attached to the end face.

[0090] Although not repeated herein for the sake of brevity, any of the features, options, and elements described herein with respect to any of the components or steps used in the process for manufacturing a wall panel including a double gasket assembly may be equally applicable to a process for manufacturing a wall panel including multiple double gasket assemblies.

[0091] Drain Duct and Gasket Connector In some embodiments, the wall system further comprises a drainage duct for draining water from the double gasket assembly or from a plurality of double gasket assemblies. As previously disclosed herein, the double gasket assembly is suitable for sealing a joint between two wall panels, the double gasket assembly comprises a support coupling, a compressible inner gasket, and a compressible outer weather gasket, the support coupling comprises a base, the base having a bottom surface and a top surface. Furthermore, the bottom surface of the base has a contact area for stabilizing the support coupling on an end surface of one of the two wall panels, the support coupling further has an attachment area for attaching the support coupling to said end surface, the top surface of the base has an inner gasket support and an outer gasket support, the top surface further comprises at least one gutter for directing water, the inner gasket support and the outer gasket support are separated by said at least one gutter, the compressible inner gasket is attached to the inner gasket support, and the compressible outer weather gasket is attached to the outer gasket support.

[0092] As shown in Figures 10 and 11, the drainage duct 100 includes a body with a mounting accessory 101 for mounting to the support coupling of the double gasket assembly, the body further includes a water collection area 102, a drainage channel 103, and a compressible gasket 104 with an external port 105, the water collection area being in fluid communication with the external port in the compressible gasket via the drainage channel, allowing water to move by gravity from the water collection area to and through the external port. The compressible gasket 104 shown in Figures 10 and 11 has a hollow flat hourglass shape with two hollow bulges. One of the bulges further has an external port 105 through which water will eventually drain out of the wall. These figures show one preferred compressible gasket shape, but other shapes are possible.

[0093] The drain duct has a mounting accessory for attaching the drain duct body to the support fitting of the double gasket assembly. In some embodiments, the mounting accessory includes at least one cavity or protrusion that matches a cavity or protrusion on the support fitting. As shown in Figures 10 and 11, in some embodiments, the drain duct can have a mounting accessory 101 having a structure for attaching the water duct body to a vertically oriented support fitting 111 of a vertically oriented double gasket assembly 112 with the water duct's catchment area at a higher vertical height than the external port in the compressible gasket of the water duct body. As shown, the mounting accessory 101 is a T-shaped protrusion sized to fit into a C-shaped outer gasket support on the support fitting base. Preferably, the drain duct is attached to the support fitting via the outer gasket support on the support fitting base. In this embodiment, the drain duct is installed using a process of vertically attaching a dual gasket assembly to the end face of a panel, where the length of the compressible outer weather gasket is cut short, i.e., its length is shorter than the support fitting, so that the compressible gasket of the drain duct can be installed within the remaining length of the support fitting.

[0094] Preferably, the compressible gasket of the drain duct further includes at least one cavity or protrusion for aligning the compressible gasket of the drain duct with the compressible outer weather gasket attached to the vertically oriented support fitting of the vertically oriented double gasket assembly. The embodiment shown in FIG. 10 includes an insertable protrusion 106 that can seat in the expansion of a similarly shaped hollow compressible outer weather gasket attached to the support fitting below the drain duct. FIGS. 11 and 12 are shown partially assembled, but without compression of the gasket for clarity, and with a portion of the gasket removed so that the interior of the junction of the double gasket assembly can be seen with respect to the water duct arrangement. Additionally, a portion of the gasket is cut away to show how the insertable protrusion 106 is inserted.

[0095] In some embodiments, the body of the drainage duct 100 has a water collection area 102, which is an open-topped funnel-shaped hopper with a three-walled rectangular inlet in fluid communication with a drainage channel 103, which terminates in a discharge outlet 107 in fluid communication with an external port 105 of a compressible gasket 104. Thus, the water collection area 102 is in fluid communication with the external port 105 by a passageway utilizing the drainage channel 103, the discharge outlet 107, and the compressible gasket 104. The passageway through the compressible gasket 104 can be achieved using an angled channel through the gasket, or in some preferred embodiments, the compressible gasket with the external port simply has a hollow center. This allows water to collect in the water collection area 102 and then flow, preferably by gravity, down the drainage channel 103 and through the discharge outlet 107 where it then enters and falls down the length of the hollow compressible gasket 104 where it then flows through and exits the external port 105 in the gasket.

[0096] In a preferred embodiment, the catchment area of ​​the drain duct is in fluid communication with at least one gutter of the dual gasket assembly. The arrangement shown in FIG. 12 illustrates the preferred arrangement and function of the drain duct. As shown, the catchment area 120 of the drain duct is aligned with and centered below the gutter 121 of the vertically oriented support fitting of the dual gasket assembly for the joint joint directly above the drain duct. In this view, a portion of the gasket attached to the dual gasket assembly has been removed to show the alignment, and the horizontal dimension of the top of the drain duct is preferably sized to extend from one gasket support to the other, meaning that any water between the gasket supports can fall into the catchment area 120. Furthermore, in this embodiment, the open top of the catchment area 120 of the drain duct is aligned above the gutter 122 of the horizontally oriented support fitting of the dual gasket assembly used to seal the joint joint directly horizontally adjacent to the drain duct. There may also be a similar, but not shown, horizontally oriented support coupling and double gasket assembly directly horizontally adjacent to the drain duct but for sealing the joint on the opposite side of the drain duct. It may be appreciated that the water in the horizontal gutter 122 (or its companion horizontal gutter on the opposite side of the depicted drain duct) is not collected in a particular catchment area 120 of the depicted drain duct. Instead, when enough water collects in the horizontal gutter 122 (or its companion horizontal gutter on the opposite side of the depicted drain duct) to cause the water to move due to leveling, the water moves to the end of the gutter and falls downward through the gutter 123, as shown by the dashed arrow in FIG. 12. The water that falls down the gutter 123 may then be collected by another catchment area of ​​a second drain duct located below the catchment area 120 and removed via that second drain duct, which may be positioned at the next junction of the double gasket assembly. It can therefore be seen that the drain duct shown in FIG. 12 can actually remove water from any number of double gasket assemblies, both vertically and horizontally oriented, sealing joints above the junction of the joints that include the drain duct shown.

[0097] The drainage duct is preferably made from a resilient material, such as a flexible and similar resilient material used to manufacture the compressible inner gasket and the compressible outer weather gasket, including elastomeric and rubber materials, including silicone and modified silicone elastomers, ethylene propylene diene monomer (EPDM) rubber, and other compressible crosslinked elastomers and other flexible polyurethanes and polyethylenes.

[0098] 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 manufacturing a panelized wall having sealed joints.

[0099] Panelized wall system The present invention also relates to a paneled wall having a sealed joint, the wall including a first wall panel, a double gasket assembly, a second wall panel, and a sealed joint between the first and second wall panels formed by the double gasket assembly. The double gasket assembly includes a compressible inner gasket, a support coupling, and a compressible outer weather gasket as described herein. Each of the first and second wall panels further has a first major surface and an opposite second major surface, and each of the first and second wall panels further has a plurality of end surfaces, each end surface being generally perpendicular to both the first major surface and the opposite second major surface of the respective first or second wall panel. The double gasket assembly is attached to only the first end surface of the first wall panel by the support coupling.

[0100] Both the compressible inner gasket and the compressible outer weather gasket of the dual gasket assembly of the first wall panel module contact and are compressed between both the first end face of the first wall panel and the first end face of the second wall panel to seal the joint between said ends.

[0101] In some embodiments, the present invention relates to a panelized wall having a sealed joint, the wall including a first wall panel module including a first wall panel and a double gasket assembly, a second wall panel, and a sealed joint between the first wall panel and the second wall panel. This embodiment is particularly useful when the panelized wall is made from prefabricated wall panel modules.

[0102] The paneled walls have a joint that includes a single double gasket assembly between the first and second wall panels forming the joint, with the support fitting of the single double gasket assembly attached to one end face of the first wall panel. However, in some embodiments, such as shown in Figure 9, the first wall panel further includes a second double gasket assembly attached to a second end face of the first wall panel, which is again attached by the support fitting of the second double gasket assembly.

[0103] Continuing with this exemplary description using two wall panels, in some embodiments, each of the first and second wall panels is a rectangular panel having a vertical height, a horizontal width, and a thickness. Thus, each of the first and second wall panels has a total of four end faces, and each wall panel can include at least two double gasket assemblies, each double gasket assembly attached to one of the four end faces on each panel by support fittings within each double gasket assembly.

[0104] In some embodiments of a panelized wall, each of the first and second wall panels is aligned such that a first major surface of a first wall panel and a first major surface of a 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, forming a set of parallel major surface planes.

[0105] In some embodiments, panelized walls having sealed joints can include inserting other types of gasket connectors in addition to or instead of drain ducts, including gasket connectors that do not have any provision for draining water. The gasket connectors of the types have a shape that matches the shape of the junction of multiple inter-panel joints or the type of connection to be made, and, if desired, are flush with the exterior surface of the panelized wall when installed in the panelized wall.

[0106] 13 and 14 show two of many possible types of gasket connectors. Each of the gasket connectors includes at least one cavity or protrusion for joining the ends of a compressible gasket, especially if the compressible gasket has a hollow center. In some embodiments, the gasket connector has at least two protrusions for attaching the ends of two separate compressible gaskets. FIG. 13 is a partially exploded view showing the joining of two gaskets with a two-way gasket connector 130. The two-way gasket connector 130 includes a body 131 with a set of two insertable protrusions 132 that can seat in an expansion between two similarly shaped hollow gaskets 133 to join the two gaskets together. This gasket connector can be used with either the compressible inner gasket or the compressible outer weather gasket, or both gaskets of a dual gasket assembly.

[0107] In some embodiments, the gasket connector has at least four protrusions for attaching the ends of four separate compressible gaskets. Figure 14 is a fully exploded view of joining four gaskets using a four-way gasket connector 140. The four-way gasket connector 140 includes a body 141 with four sets of two insertable protrusions 142 (only two sets are indicated in the figure) that can be seated in the bulge between four similarly shaped hollow gaskets 143 to join the four gaskets together. Again, the gaskets being joined can be either the compressible inner gasket or the compressible outer weather gasket, or both gaskets of a dual gasket assembly.

[0108] The gasket connector is preferably made from a resilient material, such as a resilient material that is compatible with and similar to the materials used to manufacture the compressible inner gasket and the compressible outer weather gasket, including elastomeric and rubber materials, including silicone and modified silicone elastomers, ethylene propylene diene monomer (EPDM) rubber, and other compressible crosslinked elastomers and other flexible polyurethanes and polyethylenes.

[0109] 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 for making a panel module or double gasket assembly, or for sealing a joint, can be applied to a panelized wall system having panelized walls with sealed joints.

[0110] Process for producing paneled walls with sealed joints In some embodiments, the present invention relates to a process for manufacturing a panelized wall having a sealed joint, the wall comprising a first wall panel module including a first wall panel and a double gasket assembly, a second wall panel, and a sealed joint between the first wall panel and the second wall panel. As previously described herein, the double gasket assembly includes a compressible inner gasket, a support coupling, and a compressible outer weather gasket. Each of the first and second wall panels is a rectangular panel having a vertical height, a horizontal width, and a thickness, each of the first and second wall panels further having a first major surface and an opposite second major surface. Each of the first and second wall panels further has a plurality of end faces, each end face having a length that is either a) the vertical height of the first or second wall panel, or b) the horizontal width of the first or second wall panel. Each end face also has a width that is the thickness of either the first or second wall panel, and each end face is generally perpendicular to both the first major surface and the opposite second major surface of the first or second wall panel.

[0111] The process for producing panelized walls with sealed joints includes the following steps: a) attaching a dual gasket assembly to a first end surface of a first wall panel to form a first wall panel module; b) positioning the second wall panel relative to the first wall panel module 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, 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, and both the compressible inner gasket and the compressible outer weather gasket of the dual gasket assembly are in contact with and compressed between both the first end surface of the first wall panel and the first end surface of the second wall panel to seal the joint between said end surfaces.

[0112] The positioning of the second wall panel can be done in stages as needed. For example, the second wall panel can be initially positioned so that the first and second panels are aligned in the same plane, but the gasket of the double gasket assembly between the panels is not compressed or is not fully compressed. The second wall panel can then be further positioned in plane to compress both the compressible inner gasket and the compressible outer weather gasket of the double gasket assembly between both the first end face of the first wall panel and the first end face of the second wall panel to seal the joint between said ends.

[0113] In some embodiments, the process for manufacturing a panelized wall with sealed joints may further include inserting a drainage duct at the junction of a plurality of double gasket assemblies to drain water from one or more double gasket assemblies, as described herein above. As shown in the preferred embodiment in Figures 10, 11 and 12, the drainage duct 100 includes a body having a mounting accessory 101 for mounting to a support coupling of the double gasket assemblies, the body further includes a water collection area 102, a drainage channel 103, and a compressible gasket 104 having an external port 105, the water collection area being in fluid communication with the external port in the compressible gasket via the drainage channel, allowing water to move by gravity from the water collection area to the external port and through the external port, which is preferably flush with the exterior surface of the panelized wall.

[0114] The process for producing a panelized wall may further include installing a drainage duct, as previously described herein and shown in Figures 10, 11, and 12, at the junction of the double gasket assemblies to drain water from one or more double gasket assemblies. Additionally or alternatively, the process for producing a panelized wall may include installing a gasket connector, as previously described herein, at the junction of the double gasket assemblies, the gasket connector having at least one cavity or protrusion for joining the ends of two compressible gaskets. In some embodiments, as shown in Figure 13, the gasket connector may have at least two protrusions for attaching the ends of two compressible gaskets, while in other embodiments, the gasket connector as shown in Figure 14 may have at least four protrusions for attaching the ends of four compressible gaskets.

[0115] 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 manufacturing a panelized wall having sealed joints.

Claims

1. A wall panel module comprising a first wall panel and a double gasket assembly, The first wall panel has a first main surface and a second main surface on the opposite side, and the first and second main surfaces lie within a pair of parallel planes. The first wall panel further has a first end face that is substantially perpendicular to both the first main surface and the second main surface on the opposite side. The double gasket assembly is suitable for sealing a joint between the end faces of two wall panels, the joint having length, width, and depth, and the double gasket assembly includes a support connector, a compressible inner gasket, and a compressible weather gasket. The support connector includes a base, the base has an upper surface and a bottom surface, and the upper surface further has an inner gasket support portion and an outer gasket support portion at both ends of the support connector. The compressible inner gasket is attached to the inner gasket support portion, and the compressible outer weather gasket is attached to the outer gasket support portion. Each of the compressible inner gasket and the compressible outer weather gasket has a length, and the compressible inner gasket and the compressible outer weather gasket are attached to the support coupling, where the lengths of the compressible inner gasket and the compressible outer weather gasket are parallel to each other, and the two gaskets are further bounded by the pair of parallel planes. The bottom surface of the base of the support connector further has a mounting area, and the double gasket assembly is attached to the first end face of the first wall panel via the mounting area. Wall panel module.

2. The wall panel module according to claim 1, wherein the upper surface of the base of the support connector further includes at least one drainage groove for guiding water, and the inner gasket support and the outer gasket support are separated by the at least one drainage groove.

3. A wall panel module comprising a first wall panel and a plurality of double gasket assemblies, The first wall panel has a first main surface and a second main surface on the opposite side, and the first and second main surfaces lie within a pair of parallel planes. The first wall panel further has a plurality of end faces that are substantially perpendicular to both the first main surface and the second main surface on the opposite side, and each end face has an end face width which is the thickness of the first panel and an end face length which is the length of the end face perpendicular to the end face width. Each double gasket assembly is suitable for sealing joints between the end faces of two wall panels, the joints having length, width, and depth, and each double gasket assembly includes a support connector, a compressible inner gasket, and a compressible weather gasket. Each support connector includes a base, the base having an upper surface and a bottom surface, the upper surface further having an inner gasket support portion and an outer gasket support portion at both ends of the support connector. The compressible inner gasket is attached to the inner gasket support portion, and the compressible outer weather gasket is attached to the outer gasket support portion of each support connector. Each compressible inner gasket and compressible outer weather gasket has a length, and the compressible inner gasket and the compressible outer weather gasket are attached to each support connector, where the lengths of the compressible inner gasket and the compressible outer weather gasket are parallel to each other, and the two gaskets are further bounded by the pair of parallel planes, forming each double gasket assembly. The bottom surface of the base of each support connector further has a mounting area, and each double gasket assembly is attached to the end face of the first wall panel via the mounting area. Wall panel module.

4. The wall panel module according to claim 3, wherein the upper surface of each base of the support connector further includes at least one drainage groove for guiding water, and the inner gasket support and the outer gasket support are separated by the at least one drainage groove.

5. A wall system comprising a wall panel module according to any one of claims 1 to 4.

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