Exterior Wall Panel System with Shop-Installed Fasteners
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Solution Overview
Problem
The fourth generation of the airloop system fails to meet architect demands for a hidden frame curtain wall with a grid line gap of ¼″ and allows excessive air leakage on the leeward wall due to structural engagement requirements and equipment limitations in simulating negative wind pressure.
Innovation Solution
An exterior wall panel system with a pre-assembled design using structural tape for both vision and spandrel panels, eliminating the need for field installation of rain screen and water seal members, allowing variable gridline gaps, and incorporating shop-installed fasteners for consistent quality control and reduced labor, along with jamb screws for enhanced structural integrity and air sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If structural engagement requirements are implemented in the fourth generation airloop system, then structural integrity is improved, but grid line gap increases to 3/4" which fails to meet the architect's aesthetic demand of 1/4" gap
Solution Approach 1:
The system divides the structural engagement function from the aesthetic facade presentation. The structural tape and mullion engagement provide structural integrity while the separate facade panel system allows for the desired 1/4" grid line gap aesthetic appearance.
Solution Approach 2:
The patent introduces an intermediary structural tape system that mediates between the structural requirements and aesthetic requirements. The tape provides structural engagement while allowing the facade panels to maintain the desired aesthetic gap appearance.
2Ease of manufacture
If conventional airloop system is used, then installation is simplified, but air leakage rate increases excessively on the leeward wall during high wind events
Solution Approach 1:
The system changes the pressure equalization parameters by implementing a different drainage and sealing configuration that maintains balance between windward and leeward walls, preventing the excessive negative pressure differential that causes air leakage on the leeward side.
Solution Approach 2:
Instead of allowing pressure venting on the leeward wall as in conventional systems, the patent inverts the approach by creating a pressure-balanced system where both windward and leeward walls maintain equal air leakage rates, preventing excessive infiltration on the leeward side.
3Manufacturing precision
If shop-installed fasteners are used, then manufacturing precision and quality control are improved, but device complexity and assembly time increase
Solution Approach 1:
The fasteners are pre-installed in the shop during panel fabrication, allowing quality control to be performed under controlled conditions. The pre-installed fasteners with precise positioning holes ensure consistent quality while the design simplifies field assembly by eliminating the need for field fastener installation.
Data Source
AI summary
An exterior wall panel system is provided. The exterior wall panel system includes a wall panel and a wall supporting member. The wall panel includes an exterior facia mounted to a panel perimeter frame having a head frame with an inner male panel engagement leg, a jamb frame, and a sill frame with a female panel engagement pocket. The wall supporting member includes an extruded structural member with a panel mounting flange and a shop-installed panel fastener on the panel mounting flange. The panel fastener includes a fastener stem with a stem diameter and a fastener head. The head frame or the jamb frame has a shop-fabricated jamb fastener hole for engaging the panel fastener.