Universal z-z channel for mounting wall panels to existing wall

Abstract

Disclosed is a system of cladding along an existing exterior wall of a building featuring a plurality of Z-shaped components deployed in a parallel spaced apart arrangement, with an insulation panel in between two of the Z-shaped components. The Z-shaped components having a J-wall to enforce a moisture gap between exterior wall paneling and insulation. The Z-shaped components may feature Edge-components when the line of insulation panels needs to be interrupted or when it reaches a corner or edge of a wall. The Z-shaped components and Edge components may contain a group having a plurality of air gaps. Other embodiments of Z-shaped components may contain a plurality of retaining slots that provide anchor points for holding pegs, clips and / or rods, which can then be used to secure insulation panels between adjacent Z-shaped components without unnecessarily breaching exterior sheeting. The use of clips or pegs further speeds the installation process and reduces the cost and efficiency of insulation, while improving the thermal insulation of the final assembly.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a Continuation of U.S. patent application Ser. No. 17 / 560,249, filed on Dec. 22, 2021, to the same inventor herein and entitled UNIVERSAL Z-Z CHANNEL FOR MOUNTING WALL PANELS TO EXISTING WALL, which is a Continuation-in-Part of U.S. patent application Ser. No. 17 / 203,283, filed on Mar. 16, 2021, to the same inventor herein and entitled UNIVERSAL Z-Z CHANNEL FOR MOUNTING WALL PANELS TO EXISTING WALL, which is a Continuation-in-Part of U.S. patent application Ser. No. 17 / 180,859, filed on Feb. 21, 2021, to the same inventor herein and entitled UNIVERSAL Z-Z CHANNEL FOR MOUNTING WALL PANELS TO EXISTING WALL, which is a Continuation-in-Part of U.S. patent application Ser. No. 17 / 091,255, filed on Nov. 6, 2020, to the same inventor herein and entitled UNIVERSAL Z-Z CHANNEL FOR MOUNTING WALL PANELS TO EXISTING WALL, the entire contents and disclosure of which are incorporated herein by reference.BACKGROUND OF THE INVENTION

[0002] The present invention relates generally to a wall system, and more particularly, to a system for easily mounting wall panels over an existing wall while concealing exterior insulation.

[0003] Exterior decorative works of an existing wall are exposed to elements, in particular, to moisture. Although caulking and other gap remediation techniques abound and are well known, moisture may still penetrate. Despite moisture penetration, good airflow will wick away water before mold and other destructive consequences set in. For this reason, sound construction practices, and in some instances, building code, require that exterior panels are separated from insulation by a gap of approximately 2.5 centimeters.

[0004] This gap is also highly desirable to promote conservation of energy inside building structures. Due to the principle of conduction, even insulation will transfer hot or cold onto a surface it is insulating and thus eventually lose some of its effectiveness. To overcome the loss of insulating efficiency caused by conduction, sound construction practices recommend creating an air gap between an exterior layer of exterior insulation and the layer of exterior wall paneling. This air gap creates a reflective barrier, where the hot or cold air radiating from the exterior wall panel is reflected by the insulation layer due to the presence of the air gap.

[0005] Enforcement of the air gap between the insulation layer and the exterior wall paneling is a known practice that is often dictated by the building code. However, there is presently no standard and failsafe compliance method. Instead, contractors attempt to comply by inserting a separate strip of material between the exterior paneling and the insulation. Existing methods have several serious shortcomings. The first one is higher cost and length of installation. The cost is increased due to the requirement of purchasing, stocking, and components required in ensuring that a gap is present. Secondly, installation requires a separate step involving a non-standard component. Third, it is often difficult to keep the thickness of the air gap uniform when utilizing non-standard and disparate components. Finally, the presence of an additional structural component adds to the complexity of a project and increases the risk of mistake or accident occurring due to the additional level of complexity.

[0006] Furthermore, just the presence of a gap may not be sufficient in some situations. For example, certain facades will permit a small amount of water to trickle through and behind wall cladding. This moisture needs to have a drainage outlet and must be completely ventilated to discourage accumulation of damaging moisture, mold, or mildew. Existing solutions do not adequately address the problems identified above.

[0007] Practically, the technological disclosures of this application are mounted onto exterior facades of buildings and represent an external or first line of installation that is installed outside of a waterproof layer of wall sheeting. It is therefore important to ensure that installation of insulation used at this level does not undermine the waterproofing qualities of water membranes used. Under the existing methodologies, insulation paneling is often stapled or fastened to the wall sheeting to keep it in place, which inevitably perforates the waterproof membrane. An optimal deployment would require that both rigid, semi-rigid, and flexible insulation solutions at this level can be fixed into place without having to be bolted to the wall. The solution is an attachment to the same girts that are used to attach exterior wall panels.

[0008] It is therefore desirable to provide a system that creates a single structural component which forms a frame for attaching exterior insulation to an existing wall, which also serves as a point of attachment of exterior paneling, and which enforces a uniform air gap between the exterior paneling and the layer of insulation.SUMMARY OF THE INVENTION

[0009] It is an object of the present invention to provide for a simple and uniform means of ensuring that an air gap exists between an exterior or cladding covering and a layer of exterior insulation.

[0010] It is another object of the present invention to provide a sustainable and adequate airflow between cladding panels and insulation, which among other benefits, prevents unchecked moisture buildup.

[0011] It is still another object of the present invention to provide a first moisture gap that is enforceable by the shape of the Z-girt or Z-shaped component holding the insulation panels and exterior wall panels.

[0012] It is still another object of the present invention to provide a wide first moisture gap above the insulation panels and below the cladding panels, and a second moisture gap between the insulation panels and an existing wall of the structure.

[0013] It is still another object of the present invention to provide a way of retaining insulation panels between two neighboring Z-shaped components by use of a rod spanning the two Z-shaped components.

[0014] It is still another object of the present invention to enable the use of insulation panels of varying thickness, where the panels are nonetheless securely retained between the Z-shaped components through use of rods of various thicknesses or diameters.

[0015] It is still another object of the present invention to enable the use of insulation panels of varying thicknesses where a plurality of holding pegs fitted within retention slots securely retain insulation panels of varying thickness between Z-shaped components irrespective of whether moisture draining openings are also present.

[0016] Therefore, in accordance with the present invention, a system for ensuring that exterior insulation is installed at a desired distance from shell or cladding panels includes a plurality of Z-shaped components. The plurality of Z-shaped components attach in a parallel and spaced-apart association with each other along the exterior of an existing wall. Each Z-shaped component is made of a first wall, a second wall, and a J-shaped third wall. The first wall has a first end and a second end. The first wall is preferably parallel to an existing wall and is mounted either vertically, horizontally, or diagonally thereon.

[0017] The second wall extends forwardly at an angle, preferably a right angle, from the first wall. The free end of the second wall contains the J-shaped wall. The J-shaped wall is made of two portions. The first portion is parallel to the first wall but extends in the opposite direction from the first wall. The second portion extends rearwardly from the free end of the first portion, with a free end of the second portion being located at a distance above the first wall. The first portion of the J-shaped wall is configured to accept an exterior or cladding panel bolted thereto. The J-shaped wall extends for the entire length of the Z-shaped component and forms a hollow channel that is open on one side, namely between the free end of the second portion and the second wall. In an alternative embodiment, an insert is configured to serve as a strength element and to receive the mounting bolts. The strength element is inserted into the hollow channel formed by the J-shaped portion. Additional durability cladding may be in the form of a protective bracket placed on the surface of the first wall and may include a front lip to further shield the first wall. The protective bracket is configured to receive the fastening bolt.

[0018] In another embodiment, the second wall of the Z-shaped component also comprises an upper lip. The protruding upper lip extends obliquely and at an angle, preferably a right angle, to the first side of the second wall. The upper lip is set off from the free end of the first side and is co-planar with the free end of the second portion. In an embodiment in which the second wall is not oriented perpendicularly to the first wall, the upper lip will preferably be disposed parallel to the first wall, which would translate to an acute or obtuse angle with respect to the second wall.

[0019] In another embodiment, the second wall of the Z-shaped component contains a flared section along its height. The concave section may exist throughout the length of the second wall and appear on both or one of the first and second sides of the second wall. The flared section is intended to burrow into the first end of an insulation panel adjacent to the second side and the second end of the next insulation panel that is adjacent to the first side, to induce a greater moisture seal between the adjacent components. The next insulation panel's first end will similarly be encased against a flared protrusion of the second side of the next Z-shaped component.

[0020] An edge component is disclosed. The edge component is in a spaced-apart, parallel relation to at least one Z-shaped component in the plurality of Z-shaped components deployed in parallel to each other along an existing wall. The edge component terminates a section of insulating panels. An edge component is comprised of a first wall, a second wall extending forwardly at an angle, preferably a right angle, from the first wall, and a J-shaped wall on the free end of the second wall extending in the same direction as the first wall in a parallel and spaced-apart configuration with the first wall. The J-shaped wall of the edge component is formed from a first portion and a second portion. The first portion is parallel to the first wall and configured to accept an exterior or cladding panel bolted to the exterior surface of the first portion. The free end of the second portion of the edge component terminates at a distance above the first wall. The free end of the second portion on the edge component is co-planar with the free end of the second portion of a contiguous Z-shaped component, meaning that the free ends of the second portions are at the same distance relative to the first wall of their respective first walls. The free end of either the Z-shaped component or the edge component forms and enforces the desired air gap between the exterior surface of an insulation panel and the bottom surface of an exterior panel.

[0021] The J-shaped wall of the edge component forms a hollow channel that is open on one side, namely the side between the free end of the second component and the second wall. An insert forming a strength element is disclosed for the hollow channel of the edge component. This insert is interchangeable with the insert for any of the other Z-shaped components. The insert may be placed into the hollow channel by inserting it into the opening on either side of the hollow channel or by wedging the insert into the open side of the hollow channel.

[0022] In another embodiment, the disclosed system of supporting wall cladding presents Z-shaped components having a plurality of openings to allow air to move freely between Z-shaped components. Preferably, this means that each second wall further comprises a plurality of elongated air gaps, and the second portion of the J-shaped wall also comprises air openings.BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 is a perspective view of the preferred embodiment of the Z-shaped component.

[0024] FIG. 2 is a perspective view of the preferred embodiment shown in FIG. 1.

[0025] FIG. 3 is a side elevational view of a Z-shaped component.

[0026] FIG. 3A-H demonstrates various different shapes of the second portion of the J-shaped wall of either the Z-shaped component or the edge component.

[0027] FIG. 4 is another side view of the Z-shaped component showing insulation panels installed adjacently to first and second sides of the second wall.

[0028] FIG. 5 is a perspective view of the Z-shaped component shown in FIG. 4, which also shows the concave section along the height of the second wall.

[0029] FIG. 6 is the perspective view showing the second side of the Z-shaped component shown in FIG. 5.

[0030] FIG. 7 is a sideways view of the Z-shaped component showing concave section and an external panel bolted to the outer surface of the first portion of the J-shaped wall.

[0031] FIGS. 8 and 9 demonstrate the concave section along the height of the second wall.

[0032] FIGS. 10 and 10A are perspective views of the edge component, with FIG. 10 having the flared section along the second wall.

[0033] FIG. 11 showing the sideways views of the Z-shaped component and edge component.

[0034] FIG. 12 is a view of a plurality of Z-shaped components with insulation panels installed therebetween.

[0035] FIG. 13 demonstrates an alternative embodiment of Z-shaped components with an insulation panel installed therebetween and secured with intersecting rods.

[0036] FIG. 14 is a closer view of the embodiment shown in FIG. 13.

[0037] FIG. 15 demonstrates an alternative embodiment of Z-shaped components with an insulation panel installed therebetween and secured with intersecting rods.

[0038] FIG. 16 is a closer view of the embodiment shown in FIG. 14.

[0039] FIG. 17 is a perpendicular view of the alternative embodiment of the Z-shaped component in FIG. 13.

[0040] FIG. 18 is another perpendicular view of the alternative embodiment of the Z-shaped component shown in FIG. 13, shown from another angle.

[0041] FIGS. 19 and 20 are an embodiment of a rod for retaining insulation panels between two adjacent Z-shaped components.

[0042] FIGS. 20A and 21 are detailed diagrams of an alternative embodiment of the edge component having a plurality of air slots and air openings.

[0043] FIG. 22 is another diagram of a rod for retaining insulation panels between two adjacent Z-shaped components.

[0044] FIG. 23 demonstrates a combination of the Z-shaped components together with an edge component as shown in FIG. 13.

[0045] FIGS. 24 and 25 demonstrate the method of insulating and placing wall cladding on an existing wall utilizing the Z-shaped the components and the edge components shown in the present invention.

[0046] FIG. 26 is a contextual perspective of an alternative embodiment of the present invention.

[0047] FIG. 27 is a perspective view of the Z-shaped member showing air openings and retention openings containing a holding peg.

[0048] FIG. 28 shows the opposing side of the Z-shaped member shown in FIG. 27.

[0049] FIG. 29 is a cross-sectional figure of the Z-shaped member.

[0050] FIG. 30 is perspective of another alternative embodiment of the present invention.

[0051] FIG. 31 is a perspective view of the holding peg in context of preferred usage.

[0052] FIG. 32 is a contextual perspective of another alternative embodiment of the present invention.

[0053] FIG. 33 is cross-sectional view of the Z-shaped member shown in FIG. 32. FIGS. 34 and 35 are views of the holding peg.

[0054] FIG. 36 diagrams the process of deploying clips or a rod into retaining slots that are between Z-shaped components, to secure insulation paneling.

[0055] FIG. 37 is a diagram of deployed clips and rods, that secure insulation paneling.

[0056] FIGS. 38-40 demonstrate various embodiments of the Z-shaped component having retaining slots, with the retaining slots having different shapes.

[0057] FIG. 41 is detailed contextual representation of usage of Z-shaped components as a method of securing insulation and as mount points for the attachment of wall paneling.

[0058] FIGS. 42 and 43 are contextual detailed diagram of the clip device. FIGS. 44 and 45 are contextual detailed diagram of a rod device. FIGS. 46 and 47 are detailed diagrams of the clip devices.

[0059] FIGS. 48 and 49 are detailed diagrams of the rod device.

[0060] FIGS. 50 and 51 are an additional contextual representation of the Z-shaped components and structures used therewith.DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0061] The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.

[0062] Reference will now be made in detail to embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.

[0063] Turning now descriptively to the drawings, shown in FIG. 1 is one embodiment of the Z-shaped component 10, having a first wall 20, the second wall 30 and the J-shaped wall 34. The first wall 20, having the first end 22 and the second end 24. The second wall 30 extends forwardly, at an angle, preferably a right angle, from the second end 24, or slightly offset from the second end 24, of the first wall 20. The upper lip 26 juts out laterally from the first side 32, at an angle, preferably a right angle, to the second wall 30. In the embodiment shown in FIG. 1, the second wall 30 is set off from the second end 24, and this set off creates a lower lip 28 that is co-planar with the rest of the first wall 20. The set off creating the lower lip 28 is preferably uniform for the entire length 58. A protective bracket 46 may be used to cover the surface of the first wall 20.

[0064] The free end 41 contains the J-shaped wall 34. The J-shaped wall 34 is further comprised of the first portion 36, which is substantially plane and in parallel orientation with the lower lip 28 of the first wall 20 but extends in the direction opposite to the first wall 20. The first portion 36 contains an outer surface 40, which as will be demonstrated in figures below, is configured to accept exterior wall panels 70 (FIG. 5). The second portion 38 extends rearwardly from the free end 38b of the first portion 36. Approximately halfway down along the height of the second portion 38, the second portion 38 bends towards the first side 33, with the free end 39 terminating at a distance from the second side. The structure of the J-shaped wall 34 creates a hollow channel 42, which may admit an insert 50.

[0065] While only one Z-shaped component 10 is shown in FIG. 1, preferably a plurality of Z-shaped components 10 are fastened to the exterior surface of an existing wall, in a parallel spaced apart orientation to each other, with an insulation panel 70 (FIG. 5) fitting between each two parallel Z-shaped components. The length 48 of the Z-shaped component 10 is variable and commensurate to the wall of the building or with a deployment plan of insulating panels or exterior panel. The height 53 of each Z-shaped component 10, and in particular, the second wall 30, in the plurality of such Z-shaped components, may be uniform or variable from one component to the next to support an uneven surface design of exterior wall panels, or wall panels of varied thickness.

[0066] FIG. 2 demonstrates a perspective top view of the Z-shaped component 10. Shown in figure is the first wall 20, the second wall 30, the J-shaped wall 34. The first portion 36 of the J-shaped wall 34 contains an outer surface 40. The upper lip 26 juts out laterally from the first side 32, at an angle, preferably a right angle, to the second wall 30. The lip 26 is set off from free end 41 creating a gap 25. The height of the gap 25 may be equal to or different from the depth of the hollow channel 42. The second wall 30 is set off from the second end 24 of the first wall 20, and this set off creating a lower lip 28 that is co-planar with the rest of the first wall 20.

[0067] A protective bracket 46 may be used to cover the surface of the first wall 20. The protective bracket 46 may additionally contain a flange 48 extending rearwardly. The flange 48 being adjacent to the first end 22. The protective bracket 46 accepts a fastener pierced therethrough and offers a stronger anchor location than the first wall 20. The first wall 20, as well as the overall Z-shaped component, are made from a polymeric composition which may be fibrous for strength.

[0068] Visible in FIG. 2 is the removable insert 50. The removable insert 50 is comprised of a first wall 50a. The first wall 50a is adjacent to the second wall 30. Extending laterally from the first wall 50a is a second wall 50b. The second wall 50b being adjacent to the first portion 36 of the J-shaped wall 34. Extending rearwardly from the second wall 50b is the third wall 50c. The third wall 50c being adjacent to the second portion 38 and having a shape conforming to the shape of the second portion 38. The corner 50e between the first and second walls 50a and 50b is adjacent to the angle formed by the second wall 30 and the J-shaped wall 34. The corner 50d is adjacent to the corner formed by the first portion 36 and second portion 38. The insert 50 may be introduced into the hollow channel 42 through the side openings 52 or through the gap between the free end 39 and the second side 33.

[0069] It should be appreciated that the insert 50 need not be shaped in the fashion demonstrated in FIG. 2 but can be shaped as a solid rod or cuboid. The insert 50 is intended additional strength to J-shaped wall 34 and serve as an anchor point for a fastener that carries the exterior wall paneling. The insert 50 need not be the same length as the hollow channel 42.

[0070] The J-wall 34 enforces the first moisture gap between an insulation panel and exterior decorative panel. It should be appreciated however, that the J-wall 34 need not assume the shape of a “J” but may be executed in a plurality of other shapes.

[0071] FIG. 3A-3H demonstrate some of the alternative designs for the J-wall 34. Each Z-shaped component 10 contains a first wall 20, second wall 30, and J-shaped wall 34. The J-shaped wall 34 is further comprised of the first portion 36, which is substantially plane and in parallel orientation with the lower lip 28 of the first wall 20 but extends in the direction opposite to the first wall 20. The J-shaped wall 34 is further comprised of second portion 38, for which there are many different designs. The structure of the J-shaped wall 34 creates a hollow channel 42. The upper lip 26 juts out laterally from the second wall 30, preferably at a right angle.

[0072] The first portion 36 may be at a right angle 38c with the second portion 38, with the second portion 38 not bending laterally towards the second side 33 but remaining substantially straight until the free end 39, as shown in FIG. 3A. The free end may also bend laterally to form a wall 38b that is co-planar with the lip 26, as shown in FIG. 3D. Alternatively, the first portion 36 may meet the second portion 38 at an acute angle 38c (FIG. 3B) or an obtuse angle 38d (FIG. 3E). The J-shaped wall 34 may assume a substantially trapezoidal shape (FIG. 3C), with the second wall 30 bending slightly laterally, and meeting the first portion 36 at an obtuse angle, with the first portion 36 connecting to the second portion 38 at an obtuse angle 38d and to wall 38b at an acute angle 38e, with the wall 38b being co-planar with the upper lip 26. The second portion 38 may extend rearwardly from the free end of the first portion 36 but set off at a distance from the free end, creating an overhanging extension 38f (FIG. 3F).

[0073] As shown in FIG. 3G, the second portion may be replaced by the removable insert 50. The removable insert 50 is comprised of a first wall 50a. Extending laterally from the first wall 50a is a second wall 50b, and extending rearwardly from the second wall 50b is the third wall 50c. The corner 50e is between the first and second walls 50a and 50b, and the corner 50d is between the second and third walls 50b and 50c. The third wall 50c of the insert 50 fulfills the function of the second portion 38 (FIG. 3). A flared section 80 may be placed in one or several locations along the second wall 30. The free end 43 of the insert 50 now enforces the thickness of the first moisture gap 79 (FIG. 11). As shown in FIG. 3H, the second wall 30 may be at an angle 25a to the first wall 20, that is more of an obtuse angle. The same obtuse angle 25b would then preferably be present at free end 41 of the second wall 30 if it is desirable that the first portion 36 remain parallel to the plane of the first wall 20. The upper lip 26 would preferably remain parallel to the plane of the first wall 20, creating an acute angle 26a.

[0074] FIG. 4 demonstrates the Z-shaped component 10 mounted onto an existing wall 60 with a fastener 64. The fastener 64 is shown perforating the protective bracket 46 and the first wall 20. In this respect the protective bracket 46 functions as a washer and anchor point to ensure that the first wall 20 does not fracture under the strain of the fastener 64. The protective bracket 46 may additionally contain a flange 48 extending rearwardly. The structure of the J-shaped wall 34 may admit an insert 50. The insert 50 and the protective bracket 46 permit the Z-shaped component to be manufactured out of polymers or other composite materials to minimize cost of manufacturing or weight of the overall construction, with insert 50 and the protective bracket 46 adding strength to the arrangement.

[0075] The first end 74 of each insulation panel 70 is adjacent to the second side 33 of the second wall 30 and the second end 76 is adjacent to the first side 32. Each insulation panel 70 is secured in place along its top surface 72 by the lip 26 of one Z-shaped component 10 and the free end 39 of the next Z-shaped component 10. The bottom surface 78 of each insulation panel 70 rests on the lip 28 of the first wall 20 of one Z-shaped component 10 and the first wall 20 of an adjacent Z-shaped component 10. The thickness of the first wall 20 creates the second moisture gap 62 between an existing wall 60 and each insulation panel 70.

[0076] FIG. 5 demonstrates the general deployment of Z-shaped component 10 that is shown between two insulation panels 70. The insulation panels 70 are shown contained between the upper lip 26 and J-wall 34 and the lower lip 28 on the second end 24 of the first wall 20. FIGS. 5 and 6 demonstrate an embodiment of the Z-shaped component 10 featuring a concave section 80 along the height of the second wall 30. The concave section 80 may contain a flared section on at least one side of the second wall 30 and is intended to immobilize and seal the point of contact between the second wall 30 and the first and second ends 74 and 76 of the insulating panels 70. The first side 20 contains lower lip 28, and the second wall 30 contains upper lip 26.

[0077] FIG. 7 demonstrates the full deployment of one of a plurality of Z-shaped components 10. The first wall 20 is shown attached to the existing wall 60 with a fastener 64. Protective bracket 46 functions as a washer and anchor point to ensure that the first wall 20 does not fracture under the strain of the fastener 64. The protective bracket 46 may additionally contain a flange 48 extending rearwardly. Extending forwardly at an angle, preferably a right angle, from the first wall 20 is the second wall 30. The second wall 30 is in joined communication with first and second ends 74 and 76 of the insulating panels 70, which are further immobilized by the flared section 80. An upper lip 26 captures the top surface 72 of one of the insulation panels. The set off of the upper lip 26 from the free end 41 of the second wall enforces, along the first side 32 of the second wall 30, the required first moisture gap 79, otherwise known as thermal gap. The first wall 20, containing lower lip 28, is shown creating the second moisture gap 62. The bottom surface 78 of each insulation panel 70 rests on the lower lip 28 of the first wall 20. The wall panel 90 representing an external or cladding paneling 90 is fastened to the outer surface 40 of the J-wall 34. The free end 39 of the J-wall 34 enforces the air or moisture gap 79 along the second side 33 of the Z-shaped component 10. The insert 50 is deployed within the hollow channel 42 and is also used as the anchor point for the fastener 64. The preferred thickness of the moisture gap 79 may be preferably between 1.5 and 2.5 centimeters.

[0078] FIGS. 8 and 9 further demonstrate the flared section 80 shown here to be disposed along the entire length of the second wall 30 and on both sides thereof. Alternatively, the flared section 80 may be placed in one or several locations along the length 58 or on only one of the two sides of the second wall 30. There may be a flared section 80a and 80b on either side of the second wall 30 or just on one of the sides. The insulation panels are contained between the upper lip 26 on the second wall 39, the J-wall 34, and the lower lip 28 on the first wall 20.

[0079] FIG. 10 demonstrates an edge component 110. Shown is the first wall 120, having a first end 122 and a second end 124. The first wall 120 is parallel with an existing wall 60 (FIG. 11) and being fastened thereon. Extending forwardly at an angle, preferably a right angle, from the free end, otherwise known as the second end 124, is the second wall 130. The embodiment shown further comprises flared section 180 on the second wall 130.

[0080] Extending from the free end 141 of the second wall 130 is the J-wall 134. The first portion of the J-wall 136 extends in the same direction, and in a parallel orientation as the first wall 120. The second portion 138 extends downward from the free end of the first portion 136, with the free end 139 bending toward the second wall 130 and stopping at a distance therefrom, the curvature of the J-wall 134 forming a hollow channel 142. The external or cladding paneling is fastened to the outer surface 140 of the J-wall 134.

[0081] The insert 150 is preferably present and is removably inserted into the hollow channel 142 either through the side opening 152 or through the gap between the free end 139 and the second wall 130. The insert 150 has a first wall 150a, shown substantially as a stub wall adjacent to the second wall 130. Extending laterally at an angle, preferably a right angle, from the first wall 150a, is the second wall 150b that is adjacent with and parallel to the first portion 136.

[0082] Extending downwardly from the free end of the second wall 150b is the third wall 150c, which in this embodiment is adopted to mirror the curvature of the second portion 138. It should be appreciated that the walls 150a-150c may be shaped differently and not be completely or actually adjacent to the outer walls forming the hollow channel 142. It should also be appreciated that the insert 150 may be a solid rod or cuboid or extending part of the way within the length of the hollow channel 142. It should further be appreciated that FIG. 3A-3E depicting various shapes of the J-wall 34 of the Z-shaped component 10 may be implemented with the edge component 110 with equal effectiveness. The embodiment shown in FIG. 10 demonstrates the protective bracket 146, further having the flange 148.

[0083] However, as shown in FIG. 10A, the second wall 130 need not include the flared section 180. The embodiment of the edge component 110 shown in FIG. 10A includes a protective bracket 146 that is fit to the first side 120, further having the flange 148. Extending laterally at an angle, preferably a right angle, from the first wall 120, is the second wall 130. The J-wall 134 extends from the free end of the second wall 130.

[0084] FIG. 11 demonstrates the implementation of the edge component 110 along with the Z-component 10. The edge component 110 is deployed along an existing wall 60 in a parallel, spaced apart configuration with one of a plurality of the Z-shaped components 10. An insulation panel 70 is retained between the edge component 110 and the adjacent Z-shaped component 10. The first end 74 is adjacent to the second wall 30 and the second end 76 is adjacent to the second wall 130. The embodiment shown further comprises flared section 80 on the second wall 30 and the flared section 180 on the second wall 130. However, as shown in FIG. 10A, the second wall 130 need not include the flared section 180. Either or both the Z-shaped component 10 or the edge component 110 may be deployed with the second wall thereof not featuring a flared section.

[0085] It is preferred that the free end 39 of the Z-shaped component 10, the free end 139 of the edge component 110, and the upper lip 26 of the Z-shaped component 10 are co-planar, to enforce a uniform, or minimum, moisture or thermal gap 79 between the top surface of the insulation panel and the exterior or cladding paneling 90. The exterior panel 90 is fastened to the J-wall 34 and the J-wall 134. The second moisture gap 62 is enforced by the first wall 20 and the first wall 120 of the Z-shaped component 10 and the edge component 110, respectively.

[0086] The inserts 50 and 150 are shown in this embodiment and are inserted into the space between the free end 39 and 139 and the second wall 30 and 130 of the Z-shaped component 10 and the edge component 110, respectively. The inserts 50 and 150 are used as the anchor points for the fastener 64. Protective brackets 46 and 146 also function as an anchor point to ensure that the first wall 20 and 120 do not fracture under the strain of the fastener 64. The protective brackets 46 and 146 may additionally contain a flange 48 and 148 extending rearwardly.

[0087] FIG. 12 demonstrates the plurality Z-shaped components 10, deployed in a parallel and spaced apart configuration along an existing wall 60. A plurality of parallel and spaced apart studs 60b are mounted onto the existing wall 60. The plurality of insulation panels 70 are shown, with each panel retained within the space between two adjacent Z-shaped components 10, or adjacent Z-shaped component and an edge component. A plurality of exterior wall panels 90 fastened to the J-walls 34 of the Z-shaped components 10 or / and the edge components. The J-wall 34 extends from the free end of the second wall 30, and is shown creating the first moisture gap 79. The first wall 20 is shown creating the second moisture gap 62. The structure of the J-shaped wall 34 may admit an insert 50, as shown here.

[0088] FIG. 13 demonstrates an alternative embodiment of the system of securing insulation panels using the Z-shaped component 10. Each Z-shaped component 10 has a first wall 20, a second wall 30, and a rearwardly extending wall 40a. Each Z-shaped component 10 shown contains a plurality of elongated air slots 160. The elongated slots 160 are in a parallel and spaced apart relation to each other. At least one intersecting slot 162 intersects each of the elongated slots 160. The intersecting slot 160 is configured to admit the base wall 172 of the rod 170 inserted therethrough. The rod 170 preferably has at least one second wall 174 extending at angle, preferably a right angle, from the base wall 172. The rod 170 spans the distance between two adjacent Z-shaped components 10 and is used to lock the insulation panel 70 in place. One rod 170 may intersect two or more adjacent Z-shaped components in a series of adjacently placed Z-shaped components 10 or a separate rod 170 may span each distance between any two Z-shaped components 10.

[0089] The embodiment shown in FIG. 13 is demonstrated in FIG. 14 in greater detail. Shown is a Z-shaped component 10, having a first wall 20, a second wall 30 and a rearwardly extending wall 40a. The rearwardly extending wall 40a has been previously referred to as the J-shaped wall. The shape and structure of the rearwardly extending wall 40a may vary, as provided in previous drawings. Also shown in FIG. 14 is a plurality of elongated air gaps 160 disposed at intervals throughout the second wall 30. The elongated air gaps 160 are shown to be perpendicular to the axis of the first wall 20 but may be offset at an angle thereto. Each elongated air gap 160 having an A end 164 oriented proximally or near to the free end 41 of the second wall 30, and a B end 166, oriented proximally, or near, to the first wall 20. An intersecting slot 162 intersecting the elongated air gap 160 at a distance from the A end. As shown in FIG. 14, it is preferred that all intersecting slots 162 are located at the same level and parallel with each other. Additional intersecting slots may be made along the length of the elongated air gap 160 to accommodate thinner insulation panels 70.

[0090] Still referring to FIG. 14, shown is the rod 170. The rod 170 preferably has at least one second wall 174 extending at angle, preferably a right angle, from the base wall 172. The first end 176 of the base wall 172 is inserted into one of the intersecting slots 162 and the second end 177 is inserted beneath the free end 39 of an adjacent Z-shaped component or continues through to the intersecting slot 162a of the adjacent Z-shaped component. The second wall 174 abuts the second wall 30 of one Z-shaped component 10 and the second portion 38 of the rearwardly extending wall 40a of the adjacent Z-shaped component 10 to maintain a certain degree of insertion of first and second points 176 and 177, respectively, with respect to the slots 162 and 162a. The second portion 38 extends rearwardly from the free end 38b of the first portion 36.

[0091] Appreciably there may be a separate rod inserted into each elongated air slot 160 through a corresponding slot 162a. There also may be fewer rods 170 than the number of elongated slots 160.

[0092] FIGS. 15 and 16 demonstrate how the width of the air gaps 160 on Z-shaped component 10 can be regulated using the rod 170. In FIG. 14, the second wall 174 was shown pointing away from the top surface 72, therefore, the first air gap 79 was the distance between the free end 39 and the wall panel 90 (FIG. 11). In FIGS. 15 and 16, the second wall 174 extends from the base wall 172 and points toward the top surface 72 of the insulation panel 70. Thus, the first air gap 160 has increased to account for the width of the wall 174. The insulation panel 70 is held between two Z-shaped components 10 in this embodiment, each Z-component having a rearwardly extending wall 40a comprising the first portion 36, the second portion 38, and the free end 39.

[0093] FIGS. 17 and 18 demonstrate the alternative embodiments of the Z-shaped component 10 featuring a plurality of parallel elongated air gaps 160. At least one intersecting slot 162 intersects each one of the elongated air gaps 160 preferably perpendicularly. The function of the air gaps 160 is to permit a constant flow of air flowing through the Z-shaped components 10.

[0094] This air flow provides the necessary ventilation to keep insulation panels dry and free of mold and other harmful buildup that would otherwise result from ever-present moisture. Working together and in concert with the elongated air gaps 160 is a plurality of air openings 190 made through the second portion 38 of the rearwardly extending wall 40a. The rearwardly extending wall 40a is comprised of a first portion 36, a second portion 38, and free end 39. The air openings 190 are designed to let air through even though the rest of the length of the second wall 30 may be blocked due to the presence of the insulation panel. The second wall 30 extends forwardly at an angle, preferably a right angle, from the first wall 20. The air openings 190 are preferably co-axial to or being in line and parallel with the elongated air gaps 160 but may be offset in other embodiments.

[0095] FIGS. 19 and 20 demonstrate the rod 170. Shown is the base wall 172, at least one second wall 174, a first end 176 and a second end 177. The width 175 of the second wall 174 may vary based on preference, the thickness of the insulation panel used or the air gap desired, with the greater width 175 resulting in a greater air gap if the second wall 174 is pointed toward the top surface of a panel. The shape of the second wall 174 may be rounded. The second wall 174 is shown to extend perpendicularly from free sides of the base wall 172. Alternatively, the angle of the second wall 174 with respect to the base wall 172 may be different and the second wall 174 may be disposed towards the middle of the base wall 172, or not be presented as a solid wall, but a series of protrusions.

[0096] FIG. 20A demonstrates the edge component 110 having a slightly different embodiment than shown in prior figures. Shown is the edge component 110 having a first wall 120, a second wall 130 and a forwardly extending wall 140a. The forwardly extending wall 140a is comprised of a first portion 136, which originates from at an angle, preferably a right angle, from a free end 141 of the second wall 130. The first portion is parallel to and spaced apart from the first wall 120. The second portion 138 extends downward and toward the first wall 120 and is in a parallel spaced apart arrangement with the second wall 130. The free end 139 is the most distal end of the second portion 138 and preferably is coaxial (or on the same level) as a free end 39 of a Z-shaped component 10 that is mounted adjacently to the edge component 110 (not shown here).

[0097] There is a plurality of elongated air gaps 160 shown running across the second wall 130, with the A end 164 being adjacently located to the forwardly extending wall 140a and the B end 166 being adjacently located to the first wall 120. At least one intersecting slot 162 intersects each one of the elongated air gaps 160 preferably perpendicularly. There may be additional intersecting slots 162 on each of the air gaps 160.

[0098] FIG. 21 also shows the edge component 110 with a plurality of air openings 190 along the second portion 138 above the free end 139.

[0099] FIGS. 22 and 23 demonstrate how the edge component 110 works in concert with a Z-shaped component 10. The edge component 110 is deployed along an edge of an existing wall or at an end of a section of wall cladding, where one section of a wall cladding must be interrupted. The first portion of the rearwardly extending wall 140a extends in the same direction, and in a parallel orientation as the first wall 120. The second portion 138 has free end 141 and extends downward from the free end of the first portion 136.

[0100] As shown in FIG. 22. The first end 176 of the rod 170 is mounted within one of the intersecting slots 162 of the edge component 110 and the second 177 is mounted in the intersecting slot 162 of the nearest adjacent Z-shaped component 10. The A end 164 of the air gap 160 is adjacently located to the forwardly extending wall 140a and the B end 166 is adjacently located to the first wall 120.

[0101] The width 175 and the orientation of the second wall 174 of the rod 170 determines the width of the air gap 79. Thus in FIG. 22, the second wall is pointing towards and abuts against the top surface 72 of the insulation panel 70. This configuration is required to widen the air gap 79, or when using a thinner insulation panel 70. If the rod 170 is used to secure a section of the insulation panel 70 a configuration shown in FIG. 23 is utilized. Here, the second wall 174 of the rod 170 points away from the top surface 170 and the thickness of the air gap 79 is counted from the free end 39 or 139 of the Z-shaped component 10 or the edge component 110, respectively, or from the desired level of intersecting slots 162. While the air gaps 160 are shown to be elongated, these may be formed in any shape, such as plurality of round openings, or more elliptical openings, or gaps that run across the second wall 30 or 130, and in parallel with the second wall 20 or 120.

[0102] FIGS. 24 and 25 demonstrate the method of installing wall cladding over an existing wall. The method is preferably utilized along an exterior façade of a building but may be utilized for the interior as well. Shown in FIGS. 24 and 25 are steps of mounting insulation panels onto an existing wall comprising the step of installing at least two Z-shaped components onto an existing wall 310. Followed by the step of inserting at least one insulation panel between the Z-shaped components 320. Steps 310 and 320, result locking the mounted insulation panel into place between a second walls of adjacent Z-shaped components, whether two components or a series of Z-shaped components. Steps 310 and 320 work in concert with the step 330 of configuring air circulation by having air gaps within Z-shaped components, and the step 350 of installing wall panels onto the Z-shaped components.

[0103] The disclosed method is further augmented with the step 345 of placing at least one rod through an intersecting slot in one of the Z-shaped components or between one of the Z-shaped components and the edge component, where the rod spans the distance between two adjacent Z-shaped components or a series of adjacently placed Z-shaped components. The method is further comprised of the step of utilizing the Z-shape components in combination with clips and / or rods to maintain an air gap between insulation panels and exterior wall panels 347.

[0104] FIG. 26 discloses an additional alternative embodiment demonstrating an alternative to the rod. Shown is a holding peg 240 that is configured to keep a section of an insulation panel 70. At least one holding peg is inserted into retaining slots 220. Retaining slots 220a are all on the same level and are preferably just above the top surface 72 of the insulation panel 70, such that when a plurality of holding pegs are placed within the plurality of retaining slots 220, in a one to one relationship, the holding peg 240 will adjacent to the top surface 72 and retaining the section of the insulation panel 70 securely in place. The holding peg 240 is inserted into retaining slot 220 of the Z-shaped component 10. The second portion 242 remains jutting out on the first side of the second wall 30 and is prevented from being inserted further by the lip 244. Just above the coaxial retaining slots 220a is a plurality of second air openings 202 which are located substantially near the free end 41 of the second wall 30. The plurality of second air openings 202 are shown disposed across the entire width in a single row. Alternatively, or as required, the second air openings 202 may be disposed sporadically cross some portions of the second wall 30 or in multiple rows.

[0105] Also shown in FIG. 26 is a rearwardly extending wall 40a, which in FIG. 26 is shown substantially assuming a “J” shape, comprising the first portion 36 and the second portion 38, with the free end 39 enforcing the first air gap 79. The second moisture gap 62 is an air gap that is enforced by the first wall 20 and lower lip 28 which support ends of sections of insulating panels 70.

[0106] FIGS. 27 and 28 demonstrate the embodiment of the Z-shaped component 10 shown in FIG. 26. The first wall 20 contains lower lip 28. Shown disposed substantially across the width of the second wall 30 is a plurality of second air openings 202. At least an additional plurality of air openings may be disposed at another area of the second wall 30. In FIG. 27, the additional plurality of air openings is the plurality of the third air openings 206 which are disposed in proximity to the first wall 20, or on the other side, in proximity to the lower lip 28. The plurality of third openings 206 is shown to be comprised of openings that are substantially larger than and more sparsely positioned than the plurality of second air openings 202. Alternatively, the second and third pluralities of air openings may be of equal or variably size, shape, and concentration.

[0107] Clearly demonstrated along FIGS. 27 and 28 are a plurality of retaining slots 220, which are grouped into stratified groups of coaxial retaining slots 220a, 220b, 220c and further levels, as necessary. Each strata of retaining slots 220 retains below it an insulating panel of a particular thickness.

[0108] As shown in FIG. 28, the second or third plurality of air openings 202 or 206, respectively, of the second wall 30 work in concert with air openings 190 disposed as plurality across the second portion 38 of the rearwardly extending wall 40a. The structure of the rearwardly extending wall 40a creates a hollow channel 42.

[0109] FIGS. 27 and 28 demonstrate the operational function of the holding peg 240. The first portion 246 is inserted into and through one of the retaining slots 220, until it juts out substantially on the other side of the second wall 30. The second portion 242 remains jutting out on the first side of the second wall 30 and is prevented from being inserted further by the lip 244. It is preferable that the first portion 246 fits snugly within an opening 220 and is not easily dislodged therefrom. Appreciably, when no holding peg 240 encumbers an opening 220, the free opening(s) 220 serve as another set of moisture wicking and ventilating openings.

[0110] The Z-shaped components shown in FIGS. 27 and 28 are intended to be used together with similarly airflow enabled components positioned adjacently, parallelly and in a spaced apart configuration from each other in a group featuring a plurality of parallel Z-shaped components 10. However, it is possible that ventilated Z-shaped components 10 may be used with non-ventilated Z-shaped components, or components ventilated in a differing configuration. Further, it should be appreciated that the second portion 242 retains an end of one insulating panel, while the first portion 246 retains an end of another insulating panel.

[0111] Shown in FIG. 29 is a cross-sectional view of the Z-shaped component 10 showing the first wall 20, the lower lip 28, the second wall 30 and the rearwardly extending wall 40a, comprised of the first portion 36 and the second portion 38 and having the free end 39.

[0112] FIG. 30 demonstrates yet another variation of the Z-shaped component 10 featuring a plurality of air openings. FIG. 30 demonstrates the use of multiple adjacent rows or groupings of first plurality of second openings 202a and 202b disposed in the area 30c. At the same time, the area 30d is shown not having any air openings, with heavier concentration of air openings in another area, namely, the area 30c, intended to compensate for lack of air openings in another area. The holding peg 240 is shown and is placed within openings 220 that are on the second wall 30 located adjacently to, but just below, the rearwardly extending wall 40a. The second portion 242 of the holding peg 240 remains jutting out on the first side 32 of the second wall 30 and is prevented from being inserted further by the lip 244. The second wall 30 extends outwardly at an angle from the first wall 20, which contains lower lip 28.

[0113] FIG. 31 contextually demonstrates yet another embodiment of the present invention.

[0114] Shown is the holding peg 240 that is placed within openings 220 that are located adjacently to, but just below, the rearwardly extending wall 40a. The lip 244 prevents the holding peg 240 from being inserted any further. The rearwardly extending wall 40a extends from the free end 41 of the second wall. The rearwardly extending wall 40a that is shown in this embodiment features no second portion 38 as in other figures, with the first air gap 79 being provided by the thickness of the holding peg 240 instead of the free end 39. While openings 220 are shown to be adjacent to the rearwardly extending wall 40a, the embodiment shown may utilize thinner insulation panels 70, with retaining openings 220 positioned accordingly just above such panels 70.

[0115] FIG. 32 demonstrates that the embodiment shown in FIG. 31 has no other ventilating gaps than the retaining gaps 220. Alternatively, additional gaps may be disposed on the surface of the second wall 30. Shown on the first wall 20 are openings 23, that may be used for fastening means for attaching the Z-shaped component to a wall, or for additional ventilation capability. The side of the first wall 20 that opposes the portion with the openings 23 has lower lip 28. Rearwardly extending wall 40a extends from the second wall 30, preferably at a right angle.

[0116] FIG. 33 is a cross-sectional drawing of the embodiment of the Z-shaped component 10 shown in FIG. 32. Shown is the first wall 20, the lower lip 28 co-planar with the first wall 20. A second wall 30 extends upwardly from the first wall 20 at an angle, preferably a right angle, to the first wall 20. The rearwardly extending wall 40a is comprised of the first section 36 and terminating in a free end 39.

[0117] FIGS. 34 and 35 illustrate the features of the holding peg 240. Shown are the first portion 246, the second portion 242. The first and second portions co-extensive or unitary with each other and interrupted with a lip 244. A tapered portion 248 assists with the placement of the holding peg 240 within a retaining gap. The bottom surface 249 is shown to be uniform. Alternatively, the bottom surface 249 may instead have the lip 244 or contain a lip in addition to the lip 244. Appreciably, the retaining slots 220 (FIG. 36) are configured to retain distal ends of a rod 170 and intersecting slots 162 may accommodate the holding pegs 240.

[0118] In FIG. 37, the height 53 of the second wall 30 is made in accordance with the intended insulation paneling 70 and is preferably slightly longer than the thickness 53a of an insulation panel 70, to enforce the presence of the first air gap 79. The adjacent Z-shaped members 10a and 10b shown in FIG. 36 are in a parallel and spaced apart configuration with each other, capable of having one of a plurality of insulation panels installed in the space between the parallel Z-shaped members 10a and 10b. Additional of the plurality of the insulation panels 70 are mounted in spaces 30a and 30b, and span the distance to additional adjacent Z-shaped members (not shown) or edge components 110 (FIG. 10).

[0119] Also shown in FIGS. 36 and 37 is a plurality of retaining slots 220. The retaining slots 220 are preferably coaxial and arranged in rows, such as a coaxial first row 220a and coaxial second row 220b. Each of the retaining slots 220 is configured to accept and hold, in a removable, but substantially snug association, the first portion 246 of a holding peg 240 (FIG. 35), or as disclosed in FIGS. 36 and 37, the first end 410 of the clip 400 or the first or second ends 460 or 470, respectively, of the rod 450. The clip 400 shown in FIG. 36 is comprised of the first portion 410 and a second portion 420. Each of the insulation panels 70 rests on the lower lip 28 of one adjacent Z-shaped member 10a and the first wall 20 of the opposing adjacent Z-member 10b, thus preserving the second air gap, and beneath the pegs 240, clips 400, rods 170 (FIG. 13) or rods 450 (alternative embodiment). The protruding wall 430 of the clips 400 or the protruding wall 480 of the rods 450 enforces the first air gap 79 between the top surface 72 of the insulation panels 70 and the wall paneling, which is mounted onto the rearwardly extending walls 40a. The rearwardly extending wall 40a terminates in a free end 39.

[0120] FIG. 38 is a detailed diagram of the Z-component embodiment shown in FIG. 36. The Z-component 10 having a first wall 20 that is mounted against an existing wall, which may be a waterproof membrane or exterior sheeting. A second wall 30 extending outwardly at an angle from the second end 24, preferably a right angle, said second wall having first side 32 and a second side 33. A lower lip 28 extending from the second end of the first wall 20 and is co-planar with the first wall 20. A rearwardly extending wall 40a extends from the free end 41 of the second wall 30. The rearwardly extending wall 40a extending in a co-axial but opposite direction from the first wall 20. The rearwardly extending wall 40a may be parallel to the first wall 20 or at an acute or at obtuse angle thereto. The end of the rearwardly extending wall 40a forms a free end 39. The height 53 of the second wall 30 may vary depending on the desired thickness of insulation. The space 30a houses the insulation panel. The plurality of retaining slots 220 may be placed anywhere in the area of the second wall 30, but preferably placed in rows of retaining slots such as first row 220a and second row 220b and so forth.

[0121] The retaining slots 220 may be in any shape. For example, they may be elongated and elliptical 220e (FIG. 38) and may also be rectangular or parallelogram-shaped. FIGS. 39 and 40 show alternative embodiments of the Z-shaped component with different shaped retaining slots. Each Z-shaped component in FIGS. 39 and 40 has a first wall 20, second wall 30, and a rearwardly extending wall 40a. Retaining slots 220 may be circular 220f (FIG. 39) or triangular 220g (FIG. 40), or any combination of shapes. It should be noted that any retaining slot 220 that is unobstructed by an insulation panel or not holding a peg, clip, or rod, functions as an opening for air and moisture circulation, which promotes drying in the event of moisture penetration and thus resists buildup of mold and mildew.

[0122] FIG. 41 demonstrates a contextual assembly that utilizes the Z-shaped components 10 to house exterior insulation, promote air gaps and as mount points for exterior wall paneling. Shown is the existing wall 60, which may be concrete, brick or composite wood or synthetic wall sheeting. A plurality of parallel and spaced apart studs 60b are mounted onto the wall sheeting 60. An additional layer of paneling 60c is then attached to the studs 60b, after the spaces 60a are filled with soft or sprayed insulation. A waterproof membrane 60d is spread on the exterior of the additional paneling 60c. The Z-shaped components 10 are then fastened onto the waterproof paneling 60d. The Z-shaped components 10 are preferably molded of thermally exclusionary and insulating materials and thereby complement the waterproofing of the membrane 60d. Furthermore, the completely flush and snug coupling between the membrane surface 60d and the first wall 20 of the Z-shaped components 10 forms a watertight seal that compensates for the perforation of the membrane surface 60d during installation of the Z-shaped components 10. The thickness of the first wall 20 creates the second moisture gap 62 between an existing wall 60 and each insulation panel 70.

[0123] The plurality of clips 400 and / or plurality of rods 450 secure rigid, soft or semi-rigid insulation paneling 70 that is then installed between each of the adjacent Z-shaped components 10 (or in some cases, between the Z-shaped components 10 and adjacent edge components 110). The protruding wall 430 of the clips 400 or the protruding wall 480 of the rods 450 enforces the first air gap 79 between the top surface 72 of the panels 70 and the wall paneling 90 (FIG. 7), which are mounted onto the rearwardly extending walls 40a. It should be noted that the layout of components diagramed in FIG. 41 may represent the Z-shaped components 10 that are on the exterior of a wall, or alternatively, on the interior of a wall, with rearwardly extending wall 40a mounting interior wall panels, such as plywood or composite panels or sheetrock.

[0124] FIG. 42 shows a Z-shaped component with a clip 400. The rearwardly extending wall 40a of the Z-shaped component extends from the free end of the second wall 30. The clip 400 shown in FIG. 42 is comprised of the first portion 410 and a second portion 420. The first portion 410 is configured to be lodged into a retaining slot 220. The second portion 420 is comprised of a protruding wall 430 extending from the first side 422 of the second portion 420. The extension of the protruding wall 430 is preferably equal to the minimum width of the first air gap 79. While one protruding wall 430 is shown disposed substantially lengthwise along the middle of the second portion 420, additional protruding walls 430 may be used, and may further be disposed closer to the edges of the second portion 420. The protruding wall 430 of the clips 400 enforces the first air gap 79 between the top surface 72 of the panels 70 and the wall paneling. The proximal end 430a of the protruding wall 430 abuts the first side 32 of the second wall 30 and prevents the clip 400 from sinking further than the optimal level of insertion, as shown in FIG. 43. The first portion 410 may contain a tapered section 415 and is configured to be in a substantially snug association with the retaining slots 220. Just like the peg 240 (FIG. 35), the clip 400 may be used to lock rigid insulation panels 70 into place.

[0125] FIGS. 44 and 45 demonstrate a rod 450 having a second portion 482 that spans the distance between two parallel and adjacent Z-shaped members 10. The Z-shaped members 10 are comprised of a second wall 30 with retaining slots 220. Each rod is comprised of a second portion 482 and at least one first portion 460 configured on each of the distal ends of the rod 450. The protruding wall 480 extends from the first side 452 of the rod 450. The protruding wall preferably runs throughout the length of the second portion 482 or may instead run in segments with gaps in between each segment. The protruding wall 480 enforces the first air gap 79 between the top surface 72 of the insulation panels and the wall paneling. The protruding wall 480 is shown to be substantially extending from the middle of the first side 452 but may also be disposed closer to the edges as shown in FIG. 20. The proximal end 450a terminates the protruding wall 480 and marks the optimal insertion point of the first end 460. The proximal end 450a abuts the first side 32. The rod 450 is optimally suited to secure semi-rigid or flexible insulation paneling 70 and may be used in conjunction with or as a replacement for the clips 400 or the holding pegs 240.

[0126] FIGS. 46 and 47 demonstrate the detailed features of the clip 400. The clip 400 is comprised of a first portion 410, the second portion 420, the first side 422 and the second side 433. At least one protruding wall 430 extends from the proximal end 430a until the distal end 430b. The first portion 410 may further comprise a tapered section 415, with the slope of the taper originating from the second side 433, which is the side that is adjacent to the top surface of insulation paneling. The tapered section enables an installer to introduce the clip 400 at a slight angle away from the surface of insulation paneling, so as to permit a more comfortable and secure grip of the device, and then work the clip 400 into the retaining slot. Both the clip 400 and the rod 450 (FIGS. 44 and 45) are preferably made from composite and / or thermally insulating materials.

[0127] FIGS. 48 and 49 demonstrate the rod 450, which is an alternative embodiment to the rod 170 shown in FIG. 20. The rod 450 is comprised of an elongated section portion 482 and preferably two first portions 460 and 470 on each end of the elongated second portion 482. The first surface 452 along the second portion 482 further comprises at least one protruding wall 480 that is shown to be disposed along the length of the second portion 482. The protruding wall terminates at points 450a and 450b, which mark the optimal insertion points of the first portions 460 and 470. At least one of the first portions 460 may further comprise a tapered surface 465, where the slope of the taper begins on the second side 453 to enable an angled introduction of the rod 450 during installation into a retaining slot.

[0128] FIGS. 50 and 51 are contextual diagrams demonstrating the deployment of the Z-shaped component 10 along the wall paneling 60c. As shown, the Z-shaped components 10 may be deployed coaxially with the wall studs 60b or at an angle thereto, such as at a right angle, as shown in FIG. 50. The insulation panels 70 may be retained between adjacent and parallel Z-shaped components 10 or between the Z-shaped component 10 and an adjacent edge component 112. This edge component 112 is an alternative embodiment of edge component 110 (FIG. 10), in which the rearwardly extending wall does not resemble a J-shape and is instead parallel with the first wall. The Z-shaped component 10 and the edge component 110 are fastened to the wall sheeting 60c with fasteners 64. However, no further perforations of the waterproofing membrane 60d are required to secure the paneling 70 as these can be secured using holding pegs 240 inserted into the retaining slots 220.

[0129] Although the disclosed technology is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead may be applied, alone or in various combinations, to one or more of the other embodiments of the disclosed technology, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the technology disclosed herein should not be limited by any of the above-described exemplary embodiments.

[0130] Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one,”“one or more” or the like; and adjectives such as “conventional,”“traditional,”“normal,”“standard,”“known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.

[0131] The presence of broadening words and phrases such as “one or more,”“at least,”“but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. The use of the term “module” does not imply that the components or functionality described or claimed as part of the module are all configured in a common package. Indeed, any or all of the various components of a module, whether control logic or other components, may be combined in a single package or separately maintained and can further be distributed in multiple groupings or packages or across multiple locations.

[0132] Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives may be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration. Other variations and modifications that are not specifically set out in the description herein will be apparent to those skilled in the art and the described invention is to be limited only by the scope of the following claims.

Claims

1. A wall system for providing environmental resistance, comprising:a plurality of elongate mounting members fastened to an existing wall substrate, each mounting member comprising a front face, rear face, and a connecting portion extending therebetween, said mounting members being disposed in a spaced-apart, parallel arrangement;at least one insulation panel disposed between adjacent mounting members, said insulation panel being retained in place by contact with said connecting portion; andat least one cladding panel secured to the front face of at least one of said mounting members.

2. The system of claim 1, wherein each mounting member comprises a generally U-shaped profile with a front wall and rear wall extending generally parallel to one another.

3. The system of claim 1, wherein each mounting member includes a protective bracket or fastening element configured to conform to the U-shaped profile of the mounting member, the bracket having a corresponding U-shaped configuration that reinforces the wall portion.

4. The system of claim 1, wherein the insulation panel is retained between an edge component, a Z-shaped mounting member, or another mounting member configured to engage and support an insulation panel.

5. The system of claim 1, wherein each mounting member includes a protective bracket that may be configured to receive a fastening element.

6. The system of claim 1, wherein each mounting member further comprises retention slots configured to receive clips, rods, or holding pegs for securing insulation panels.

7. The system of claim 1, wherein at least one mounting member is configured to receive a removable insulation-retention clip having a first portion configured to engage the mounting member and a second portion configured to bear against a surface of an insulation panel so as to retain the insulation panel in place without penetrating it.

8. The wall system of claim 1, wherein each mounting member includes a retention portion that can be inserted into the connecting portion, the retention portion being a clip that is configured to engage an edge of an insulation panel without penetrating the insulation panel, and being positionable to accommodate insulation panels of varying thickness.

9. The system of claim 1, wherein each mounting member further comprises an upper lip extending laterally from an upper portion of said connecting portion, the upper lip being positioned to engage and retain an upper edge of said insulation panel and wherein the placement of said upper lip is adjustable along said connecting portion to accommodate variations in the termination height of said insulation panel.

10. The system of claim 1, wherein each mounting member includes elongated air slots along the bridging portion to facilitate airflow between insulation and cladding.

11. The system of claim 1, wherein each mounting member comprises a Z-shaped profile having a wall that includes a plurality of elongated air openings or slots configured to provide ventilation and drainage between adjacent mounting members and to maintain a moisture-draining cavity behind exterior cladding or insulation.

12. The system of claim 1, wherein each mounting member further comprises a reinforcing bracket disposed along a wall of the mounting member, the reinforcing bracket having a shape generally conforming to the wall and secured thereto so as to strengthen the mounting member.

13. The system of claim 1, wherein each mounting member includes a lip, flange, retention structure, or flared section along one of its walls, the lip, flange, retention structure, or flared section being configured to engage, secure, or immobilize ends or edges of adjacent insulation panels at a point of contact.

14. The system of claim 1, wherein each mounting member is configured to receive a fastener for securing at least one of its walls to exterior wall paneling.

15. A wall system for providing environmental resistance, comprising:a plurality of elongate mounting members, each mounting member comprising a rear face configured to be fastened to a wall substrate, a front face configured to receive a cladding panel, and a connecting portion extending between the rear face and the front face;at least one insulation panel disposed between adjacent mounting members and supported in part by at least one lip extending from the bridging portion or the front or rear face; andat least one cladding panel attached to the front face or a return portion of at least one mounting member, wherein said connecting portion is dimensioned to accommodate insulation panels of varying thickness.

16. The system of claim 15, wherein each mounting member comprises a lip extending laterally from a lower region of a wall of the mounting member, the lip being configured to underlie and support an edge of an insulation panel so as to retain the insulation panel between adjacent mounting members.

17. The system of claim 15, wherein the wall of each mounting member includes a pitched or flared lip section on the front face oriented toward an adjacent insulation panel, the lip section being configured to retain the insulation panel in cooperation with fasteners securing the mounting member to a wall substrate.

18. The system of claim 15, wherein each mounting member further comprises an upper lip extending obliquely from an upper region of a wall of the mounting member, the upper lip being generally parallel to a free end of an adjacent mounting member.

19. The system of claim 15, wherein each mounting member further comprises a return portion extending from the connecting portion, the return portion being configured to support or engage a cladding panel.

20. The system of claim 15, wherein the wall system defines at least one moisture gap between the insulation panel and one of a cladding panel or an existing wall substrate to promote thermal separation and drainage of moisture.

21. A wall system for providing environmental resistance, comprising:a plurality of elongate mounting members, each mounting member comprising a rear face configured to be fastened to a wall substrate, a front face configured to receive a cladding panel, a connecting portion extending between the rear face and the front face, and a return portion extending from the connecting portion, the return portion being configured to support or engage the cladding panel;a flared section formed along at least a portion of the front face and configured to engage adjacent edges of insulation panels;a channel defined at least in part by the return portion and the front face;a removable insert disposed within the channel, the insert configured to provide reinforcement and receive a fastener; anda protective bracket disposed along the first wall, the bracket comprising a flange extending rearwardly to overlap an edge of an insulation panel;a plurality of insulation panels disposed between adjacent mounting members and retained by the flared section and the flange; andat least one cladding panel fastened to the support portion, wherein the flared section, insert, and protective bracket cooperate to enforce a uniform first air gap between the insulation and the cladding and a second air gap between the insulation and the existing wall.

22. A method of providing environmental resistance to a building, comprising:fastening a plurality of elongate mounting members to a wall substrate, each mounting member comprising a front face, a rear face, and a connecting portion extending therebetween;inserting at least one insulation panel between adjacent mounting members such that said insulation panel is retained in place by the connecting portion; andattaching at least one cladding panel to the front face of at least one of said mounting members.

23. The method of claim 19, wherein each mounting member comprises a generally U-shaped profile with a front wall and rear wall extending generally parallel to one another.

24. The method of claim 19, wherein each mounting member includes a protective bracket configured to receive a fastening element.

25. The method of claim 19, wherein each mounting member further comprises retention slots configured to receive clips, rods, or holding pegs for securing the insulation panels.

26. The method of claim 19, wherein each mounting member further comprises an upper lip extending laterally from an upper portion of said connecting portion, the upper lip being positioned to engage and retain an upper edge of said insulation panel and wherein the placement of said upper lip is adjustable along said connecting portion to accommodate variations in the termination height of said insulation panel.

27. The method of claim 19, wherein each mounting member is configured to receive a fastener for securing at least one of its walls to exterior wall paneling.

28. The method of claim 19, wherein each mounting member includes elongated air slots along the connecting portion to facilitate airflow between the insulation and cladding.

29. The method of claim 19, wherein each mounting member includes a lip, flange, or retention structure configured to secure or immobilize ends of adjacent insulation panels during said inserting step.

30. The method of claim 19, wherein each mounting member includes a flared section along one of its walls configured to engage the insulation panel at a point of contact to improve retention and sealing.

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