Note: Descriptions are shown in the official language in which they were submitted.
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CURTAIN WALL SYSTEM AND COMPONENTS THEREOF
FIELD OF THE INVENTION
[0001] The present invention is a curtain wall system to be
secured to a building
structure.
BACKGROUND OF THE INVENTION
[0002] Curtain wall systems, which typically include panels
including glass panes and
other materials, are well known in the art. The curtain wall is secured to a
frame of a structure
(e.g., a multi-storey building) to provide the exterior facade of the
structure.
[0003] The curtain wall system typically is not load-bearing,
except to the extent that it
bears its own weight. During installation of a unitized curtain wall, the
panels are connected to
each other. In designing the curtain wall system, a number of factors
typically are considered.
For example, the method of installing the panels to form the curtain wall
system ideally should
be relatively simple in practice, because of the significant costs that may
otherwise be incurred.
However, the known methods of installation are still relatively complex.
[0004] Also, although the thermal efficiency of the known
curtain wall systems has been
improving, it is generally thought to be somewhat unsatisfactory. In addition,
the prior art
curtain wall systems typically provide only a limited number of options for
designers (e.g.,
architects) regarding the appearance of the installed curtain wall system.
SUMMARY OF THE INVENTION
[0005] There is a need for a curtain wall system that overcomes
or mitigates one or more
of the disadvantages or defects of the prior art. Such disadvantages or
defects are not necessarily
included in those listed above.
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[0006] In its broad aspect, the invention provides a curtain wall system
to be secured to a
building structure between the building structure and an external space. The
curtain wall system
includes a number of panel units attachable to each other respectively, each
panel unit including
a first mullion segment, a second mullion segment, one or more panels
positioned between the
first and second mullion segments, and one or more transverse mullion
segments. The first
mullion segment includes an elongate first main portion extending between
first top and bottom
ends thereof and having a first exterior side thereof. The second mullion
segment includes an
elongate second main portion extending between second top and bottom ends
thereof and
comprising a second exterior side thereof. The transverse mullion segment is
selected from the
group consisting of first and second transverse mullion segments, and is
secured between the
first and second exterior sides of the first and second main portions to
locate the first and second
main portions spaced apart from each other by a preselected distance. The
panel is held between
the first and second mullion segments and transverse mullion segment(s). The
first mullion
segment of each of the panel units is attachable to a secured second mullion
segment of a first
installed one of the panel units having a secured panel and installed on the
building structure, to
provide a mullion assembly defining a central cavity therein in which a
central volume of air is
isolated for at least partially thermally insulating the building structure
relative to the external
space. The first and secured second mullion segments, when attached together,
additionally
defining a boundary region between' the central cavity and the external space.
Each mullion
assembly includes one or more thermal insulator elements at least partially
positioned between
the panel and the secured panel to at least partially define one or more
thermal breaks between
the external space and the boundary region.
[0007] In another aspect, the thermal insulator element extends between
an inner end
thereof that is secured in the boundary region and an outer end thereof that
is positioned in a
preselected position relative to the panel and the secured panel.
[0008] In another of its aspects, the invention provides a mullion
assembly for securing
one or more first panels in a predetermined position relative to one or more
second panels on a
building structure between the building structure and an external space. The
mullion assembly
includes a first mullion segment of the first panel, a second (secured)
mullion segment of the
second panel installed on the building structure, and one or more thermal
insulator elements.
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The first mullion segment includes an elongate first main portion extending
between inner and
outer ends thereof, and an elongate first inner portion attached to the first
main portion at the
inner end and extending substantially orthogonally from the main portion, the
first inner portion
defining an inner aperture therein. The first mullion segment also includes a
first outer portion
attached to the first main portion at the outer end and extending
substantially orthogonally from
the main portion, the first outer portion defining an outer aperture therein.
The first panel
includes a first glazing unit secured to the first outer portion and at least
partially positioned
between the external space and the first outer portion. The second (secured)
mullion segment
includes an elongate second main portion extending between inner and outer
ends thereof, and an
elongate second inner portion attached to the second main portion at the inner
end and extending
substantially orthogonally from the main portion, the second inner portion
comprising an inner
peg at least partially receivable in the inner aperture of the first inner
portion. The second
mullion segment also includes a second outer portion attached to the second
main portion at the
outer end and extending substantially orthogonally from the main portion, the
second outer
portion comprising an outer peg at least partially receivable in the outer
aperture. The second
panel also includes a second glazing unit secured to the second outer portion
and at least partially
positioned between the external space and the second outer portion. Upon the
inner peg and the
outer peg being at least partially received in the inner and outer apertures
respectively, to attach
the first and second inner portions together and to attach the first and
second outer portions
together respectively, the first and second mullion segments are attached to
each other, securing
the first panel in the predetermined position relative to the building
structure, and defining a
central cavity in which a central volume of air is isolated for at least
partially thermally
insulating the building structure relative to the external space, the first
and second outer portions
collectively defining a boundary region between the central cavity and the
exterior space. The
thermal insulator element is at least partially positionable between the first
panel and the second
panel, to at least partially define the thermal break(s) between the external
space and the
boundary region.
[0009]
In yet another aspect, the mullion assembly additionally includes a cover
element
attached to the thermal insulator element. The cover element is formed to
engage preselected
portions of each of the first and second glazing units upon the attachment of
the first and second
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mullion segments to each other to at least partially define the thermal
break(s) between the
external space and the boundary region.
[0010] In another aspect, the thermal insulator element alternatively
includes an external
engagement portion engageable with the first panel and the second panel to at
least partially
define the thermal break(s) between the external space and the boundary
region.
[0011] In another of its aspects, the invention provides a transverse
mullion assembly for
securing a first panel in a preselected position relative to a second
(secured) panel on a building
structure between the building structure and an external space. The transverse
mullion assembly
includes a first transverse mullion segment, a second (secured) transverse
mullion segment, a
gasket, and one or more transverse thermal insulator elements. The first
transverse mullion
segment is included in a first panel unit that is to be attached to a second
panel unit, the second
panel unit having previously been secured to the building structure, and to
one or more other
panel units. The second transverse mullion segment is included in the second
(secured) panel
unit. The first transverse mullion segment includes an elongate first main
transverse portion
extending between inner and outer ends thereof The first main transverse
portion includes a first
body segment having first front and rear walls and one or more first side
walls at least partially
defining a transverse central region in which a transverse central volume of
air is isolated for
thermally insulating the building structure relative to the external space.
The first transverse
mullion segment also includes a first outer portion attached to the first main
transverse portion at
the outer end and extending substantially orthogonally from the first main
transverse portion.
The first outer portion and the front wall define a slot therebetween. The
first panel includes a
first glazing unit secured to the first outer portion and at least partially
positioned between the
external space and the first outer portion. The second transverse mullion
segment includes an
elongate second main transverse portion extending between inner and outer ends
thereof The
second main transverse portion includes a second body segment having second
front and rear
walls and one or more second side walls at least partially defining a second
central region in
which a second central volume of air is isolated for thermally insulating the
building structure
relative to the external space. The second body segment includes a second
outer portion
positioned outwardly relative to the second central region. The second
transverse mullion
segment also includes an arm subassembly attached to the second main
transverse portion and
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having an arm extending substantially orthogonally from a base of the arm
subassembly secured
to the second side wall of the second main transverse portion, the arm being
at least partially
receivable in the slot in a secured position in which the arm is sealably
engaged with the first
outer portion and the first front wall. The second panel includes a second
glazing unit secured to
the second outer portion and at least partially positioned between the
external space and the
second outer portion.
[0012] The gasket is at least partially positionable between the first
and second transverse
mullion segments between the arm and the external space when the arm is in the
secured position
in the slot to at least partially thermally insulate the building structure
relative to the external
space. When the arm is in the secured position in the slot, the first and
second outer portions and
the arm define a separation region between the transverse central region and
the external space.
The transverse thermal insulator element is at least partially positionable
between the first and
second panels, to at least partially define one or more thermal breaks between
the external space
and the separation region.
[0013] In another of its aspects, the transverse mullion assembly is at
least partially
secured between first and second mullion segments.
[0014] In yet another of its aspects, the invention provides an
intermediate mullion
assembly for securing an upper panel and a lower panel relative to a building
structure between
the building structure and an external space. The intermediate mullion
assembly includes an
intermediate body defining an intermediate cavity therein in which air is
isolated for at least
partially thermally insulating the building structure relative to the external
space. The
intermediate body is securable to the upper and lower panels. The intermediate
mullion
assembly also includes one or more intermediate thermal insulator elements at
least partially
positionable between the upper and lower panels, to at least partially define
one or more thermal
breaks between the external space and the intermediate body.
[0015] In another aspect, the invention provides a jamb mullion assembly
for securing a
panel in a selected position relative to a building structure between the
building structure and an
external space. The jamb mullion assembly includes a jamb mullion body
defining a jamb
mullion cavity therein in which air is isolated for at least partially
thermally insulating the
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building structure relative to the external space. The panel includes a
glazing unit that is secured
to the jamb mullion body and extending from a preselected side of the jamb
body. The jamb
mullion body additionally includes a closed side that is secured to the
building structure.
[0016] In yet another aspect, the invention provides a method
of securing a first panel
unit in a predetermined position relative to a building structure between the
building structure
and an external space. The method includes engaging a first mullion segment
with a
substantially vertical second mullion segment, to attach the first and second
mullion segments to
each other to define a central cavity therein at least partially defined by a
boundary region in
which a central volume of air is isolated for thermally insulating the
building structure relative to
the external space. (The second mullion segment is included in a second panel
unit that is
attached to the building structure, being previously secured thereto, and to
one or more panels.)
One or more thermal insulator elements are positioned between the boundary
region and the
external space, for thermally insulating the building structure relative to
the external space.
While the first mullion segment is attached to the second mullion segment, a
first transverse
mullion segment is engaged with a substantially horizontal second transverse
mullion segment,
to attach the first and second transverse mullion segments to each other to
provide a transverse
central region in which a transverse central volume of air is substantially
isolated to at least
partially insulate the building structure relative to the external space, the
engaged first and
second transverse mullion segments defining a separation region between the
building structure
and the external space. Also, one or more transverse thermal insulator
elements are positioned
between the separation region and the external space, for thermally insulating
the building
structure relative to the external space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention may be better understood with reference to
the attached drawings,
in which:
[0018] Fig. 1A is a front view of an embodiment of a curtain
wall system of the
invention, partially installed on a building structure;
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[0019] Fig. 1B is a schematic side view of the curtain wall system of
Fig. 1A and the
building structure on which the curtain wall system is partially installed;
[0020] Fig. 2A is a cross-section of an embodiment of a mullion assembly
of the
invention prior to installation thereof, drawn at a larger scale;
[0021] Fig. 2B is a cross-section of an alternative embodiment of the
mullion assembly
of the invention, prior to installation thereof;
[0022] Fig. 3 is an isometric view of an alternative embodiment of the
curtain wall
system of the invention showing an unattached panel unit in position to be
attached to other
panel units of the system, drawn at a smaller scale;
[0023] Fig. 4A is a cross-section of first and second transverse mullion
segments of the
invention prior to their attachment to each other to form a transverse mullion
assembly of the
invention, drawn at a larger scale;
[0024] Fig. 4B is a cross-section of the transverse mullion assembly of
the invention
formed by the attachment of the first and second transverse mullion segments
of Fig. 4A with
each other;
[0025] Fig. 4B is a cross-section of an alternative embodiment of the
transverse mullion
assembly of the invention;
[0026] Fig. 5A is a cross-section of another embodiment of the mullion
assembly of the
invention;
[0027] Fig. 5B is a cross-section of another embodiment of the mullion
assembly of the
invention;
[0028] Fig. 6A is a cross-section of an embodiment of a jamb mullion
assembly of the
invention;
[0029] Fig. 6B is a cross-section of an alternative embodiment of the
jamb mullion
assembly of the invention;
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[0030] Fig. 7A is a cross-section of another alternative embodiment of
the mullion
assembly of the invention;
[0031] Fig. 7B is a cross-section of another alternative embodiment of
the mullion
assembly of the invention;
[0032] Fig. 7C is a cross-section of a portion of the mullion assembly of
Fig. 7B, drawn
at a larger scale;
[0033] Fig. 8A is a cross-section of another alternative embodiment of
the mullion
assembly of the invention, drawn at a smaller scale;
[0034] Fig. 8B is a cross-section of another alternative embodiment of
the mullion
assembly of the invention;
[0035] Fig. 9A is an exploded isometric view of an embodiment of a panel
unit of the
invention from which certain elements have been omitted, drawn at a smaller
scale;
[0036] Fig. 9B is an isometric view of portions of an embodiment of the
mullion
assembly of the invention as assembled, with transverse mullion assemblies and
intermediate
mullion assemblies secured thereto, drawn at a larger scale;
[0037] Fig. 10A is a side view of segments of the transverse mullion
assemblies and the
intermediate mullion assembly of Fig. 9A, drawn at a larger scale;
[0038] Fig. 10B is a cross-section of the intermediate mullion assembly
of Fig. 10A,
drawn at a larger scale;
[0039] Fig. 11A is an isometric view of front sides of abutting second
transverse mullion
segments with a silicone splice sheet positioned thereon, drawn at a larger
scale;
[0040] Fig. 11B is an isometric view of rear sides of the abutting second
transverse
mullion segments of Fig. 11A with a reinforcing and alignment angle element
positioned
thereon;
[0041] Fig. 11C is an isometric view of the reinforcing and alignment
angle of Fig. 11B;
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[0042] Fig. 11D is a side view of the reinforcing and alignment angle
element of Fig.
11B;
[0043] Fig. 11E is a cross-section of an embodiment of the second
transverse mullion
assembly of the invention including the silicone splice sheet of Fig. 11A and
the reinforcing and
alignment angle element of Figs. 11B-11D; and
[0044] Fig. 12 is an isometric view of the rear side of the second
transverse mullion
segment of Fig. 11A with certain other additional elements.
DETAILED DESCRIPTION
[0045] In the attached drawings, like reference numerals designate
corresponding
elements throughout. Reference is first made to Figs. 1A-5B and 9A-10B to
describe an
embodiment of a curtain wall system in accordance with the invention indicated
generally by the
numeral 20. As will be described, the curtain wall system 20 preferably is
secured to a building
structure 22 (Figs. 1A, 1B) between the building structure 22 and an external
space 24 (Fig. 1B)
relative thereto. In one embodiment, and as can be seen in Figs. 1A and 3, the
curtain wall
system 20 preferably includes a plurality of panel units 26 attachable to each
other respectively.
Preferably, each panel unit 26 includes a first mullion segment 28, having an
elongate first main
portion 30 extending between first top and bottom ends 32, 34 thereof and
including a first
exterior side 36 thereof (Figs. 2A, 9A), and a second mullion segment 38,
having an elongate
second main portion 40 extending between second top and bottom ends 42, 44
thereof and
including a second exterior side 46 thereof (Figs. 2A, 9A). As will also be
described, each panel
unit 26 preferably also includes one or more panels 48 positioned between the
first and second
mullion segments 28, 38 (Figs. 1A, 2A-3).
[0046] It is also preferred that each panel unit 26 includes one or more
transverse mullion
segments 49 (Fig. 3). The transverse mullion segment 49 included in the panel
unit 26
preferably is selected from the group consisting of the first and second
transverse mullion
segments 50, 52 (Figs. 4A, 4B). Such transverse mullion segment 49 preferably
is secured
between the first and second exterior sides 36, 46 of the first and second
main portions 30, 40 to
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locate the first and second main portions 30, 40 spaced apart from each other
by a preselected
distance "D" (Figs. 1A, 3). It is also preferred that the panel 48 is held
between the first and
second mullion segments 28, 38 and the transverse mullion segment(s) 49 (Fig.
3).
[0047] Preferably, the first mullion segment 28 of each panel unit 26 is
attachable to a
secured second mullion segment 38' of a first installed panel unit 26' (Figs.
1A, 3), to provide a
mullion assembly 54 defining a central cavity 56 therein in which a central
volume of air is
isolated for at least partially thermally insulating the building structure 22
relative to the external
space 24, as will also be described (Fig. 5A). The installed panel unit 26'
preferably includes a
secured panel 48' (Fig. 1A). As will also be described, when they are attached
together, the first
and secured second mullion segments 28, 38' additionally define a boundary
region 58 between
the external space 24 and the central cavity 56 (Fig. 5A). It is also
preferred that, as can be seen
in Fig. 5A, each mullion assembly 54 includes one or more thermal insulator
elements 60 at least
partially positioned between the panel 48 and the secured panel 48' to at
least partially define one
or more thermal breaks "U", "Z" between the external space 24 and the boundary
region 58.
[0048] It will be understood that the thermal insulation or thermal break
provided by
various elements of the invention described herein retards the passage of heat
therethrough.
Accordingly, references herein to "thermal insulation" or a "thermal break" or
variants thereof
will be understood to be references to thermal insulation that may permit
transfer of some heat
therethrough. Also, it will be understood that references herein to a volume
of air being
"isolated" mean that the volume of air is generally dead, and generally not
subjected to
movement thereof or drafts, but also that the volume of isolated air or
portions thereof may be
subjected to movement or drafts from time to time, i.e., the isolation of the
volume of air is not
necessarily complete.
[0049] As can be seen in Fig. 5A, in one embodiment, the thermal breaks
"U" and "Z"
preferably are located on opposite sides of the thermal insulator element 60.
The thermal breaks
"U" and "Z" are air spaces in which air is isolated. In the embodiment
illustrated in Fig. 5A, the
thermal breaks "U" and "Z" preferably extend between the boundary region 58
and a cover
element 93. In Fig. 5A it can be seen that, partly because of wiper elements
"WII" and "WI2"
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that are positioned between the respective panels 48, 48' and the cover
element 93, the air spaces
"U" and "Z" are isolated.
[0050] As can be seen in Figs. 1A and 3, once the panel unit 26 is
installed, the first
installed panel unit 26' is positioned beside the panel unit 26. As
illustrated in Figs. 1A and 1B,
the curtain wall system 20 preferably is secured to the building structure 22
by a number of
anchors "A", as is known in the art. It will be understood that the
illustrations of the anchors in
Figs. 1 A and 1B are symbolic representations, and details of the anchors "A"
have been omitted
for clarity of illustration. Because the anchors "A" are conventional, no
further description
thereof is required.
[0051] The building structure 22 illustrated in Fig. 1B is also
conventional, and typically
includes vertical members "V" connected with horizontal members "H" (Figs. 1A,
1B). Those
skilled in the art would appreciate that the horizontal members typically
include floors in the
building, or support the floors, and that the building would include numerous
elements (e.g., for
HVAC, and other services) that are not shown for clarity of illustration.
Further details of the
building structure relating to the floors and other elements are omitted from
Fig. 1B for clarity of
illustration. Those skilled in the art would also appreciate that the building
structure 22
illustrated in Fig. 1B is exemplary only, and that the building structure 22
may have any suitable
configuration.
[0052] Those skilled in the art would also appreciate that the design of
the panel units 26
as illustrated in Figs. 1A and 3 is also exemplary only. As illustrated, in
one embodiment, the
panel unit 26 preferably includes an upper panel 48U and a lower panel 48L,
divided by an
intermediate mullion assembly 66. As will be described, and as can be seen in
Figs. 1A and 3, in
each panel unit 26, the intermediate mullion assembly 66 preferably is secured
between the first
and second mullion segments 28, 38.
[0053] It can also be seen in Fig. 1A that, when the panel unit 26 is
installed, the upper
panel 48U preferably is positioned proximal to the horizontal member "H" of
the building
structure 22. It will be understood that the upper panel 48U may be opaque, or
partially opaque,
so that the horizontal member "H" and building elements associated therewith
are not viewable
(or, not easily viewable) from the external space 24, once the curtain wall
system 20 is installed.
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In one embodiment, although the upper panel 48U preferably is opaque or
partially opaque, the
lower panel 48L preferably has any suitable appearance. The lower panel 48L
may have any
suitable appearance, e.g., it may be translucent, or clear, or combinations
thereof.
[0054] Those skilled in the art would appreciate that the design of the
panel units 26 may
take many forms. The specific design of the panel units 26 that is illustrated
(i.e., with upper and
lower panels 48U, 48L, and the intermediate mullion assembly 66 positioned
therebetween) is
only one example of the design of the panel unit 26. For clarity of
illustration, however, only
one design of the panel unit 26 is shown in the drawings herewith.
[0055] As can be seen in Figs. 2A, 2B, and 5A, in one embodiment, the
curtain wall
system 20 preferably includes the cover element 93. In this embodiment, the
wiper elements
"W11" and "WI2", which are included in the cover element 93, sealably engage
the panels 48, 48'
respectively.
[0056] An alternative embodiment, illustrated in Fig. 5B is described
further below. In
the alternative embodiment of Fig. 5B, air spaces "UB" and "ZB" are partially
defined by a
thermal insulator element 60B, in the absence of the cover element. The air
spaces "UB" and
"ZB" contain isolated air volumes therein. As can be seen in Figs. 2A, 2B, 5A,
and 5B, in one
embodiment, it is preferred that the thermal insulator element 60 extends
between an inner end
62 thereof that is secured in the boundary region 58 and an outer end 64
thereof that is positioned
in a preselected position relative to the panel 48 and the secured panel 48'
(Fig. 2A). The
thermal insulator element 60 is positioned to at least partially insulate the
boundary region 58
relative to the external space 24. As can be seen in Fig. 5A, when the thermal
insulator element
60 is attached to the cover element 93, the thermal insulator element 60 at
least partially defines
the air spaces "U" and "Z", in which air is isolated.
[0057] From the foregoing, it can be seen that the preselected position
of the outer end of
the thermal insulator element varies and the outer end may have different
configurations,
depending on the embodiment of the mullion assembly. In the embodiment
illustrated in Fig.
5A, the preselected position in which the outer end 64 is located is outwardly
relative to the
panels 48, 48', and the cover element 93 is secured to the outer end 64 of the
thermal insulator
element 60. However, in the embodiment illustrated in Fib. 5B, the outer end
of the thermal
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insulator element is formed to engage each of the panels 48, 48', and the
outer end is positioned
generally between the panels, as will be described.
[0058] As can be seen in Fig. 5A, when the first and second mullion
segments 28, 38' are
joined together, the central cavity 56 is defined, in which air is isolated.
The isolated air in the
central cavity 56 serves to at least partially thermally insulate the building
structure 22 relative to
the external space 24. Also, the boundary region 58 provides support for the
thermal insulator
element 60 extending outwardly therefrom to define the additional isolated air
spaces "U" and
"Z" that are located between an outer element (in Fig. 5A, the cover element
93) and the
boundary region 58. These additional isolated air spaces provide additional
thermal insulation
between the external space 24 and the building structure 22, i.e., in addition
to the isolated air in
the central cavity 56.
[0059] In addition, in one embodiment, the boundary region 58 preferably
includes the
pockets 96' and 94 of isolated air (Figs. 2A, 2B). These isolated air pockets
provide additional
thermal insulation.
[0060] It can also be seen in Fig. 5A that the structure of the boundary
region 58, with
the thermal insulator element 60 extending therefrom toward the external space
24, provides
substantial flexibility to the designer, because different external elements
(e.g., the cover element
93) may be secured to the boundary region 58 without materially affecting the
effectiveness of
the thermal insulation provided by the joined mullion segments. The cover
element 93 may be
provided in a wide variety of forms, and in each case, thermal breaks "U" and
"Z" may be
defined between the cover element 93 and the boundary region 58.
[0061] In one embodiment, illustrated in Fig. 2A, the second outer
portion 85' preferably
includes a slot "SLI" in which the inner end 62 of the thermal insulator
element 60 is securely
receivable. In another embodiment, illustrated in Fig. 2B, the inner end 62A
of the thermal
insulator element 60A preferably is securely receivable in a slot "SL2" that
is formed in the first
outer portion 77A. Accordingly, it can be seen that the boundary region 58 is
defined by an
outer wall "W1" when the mullion segments are joined together, and the thermal
insulator
element 60 is mounted, at its inner end, in the outer wall "Wi" (Fig. 5A).
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[0062] Also, as noted above, the thermal insulator element 60 may be
provided in various
forms. For example, one alternative design is illustrated in Fig. 5B, in which
the thermal
insulator element is exposed to the external space 24, in the absence of a
cover element, as will
be further described below.
[0063] From the foregoing, it can be seen that the design of the mullion
assembly, in
which the thermal insulator element extends outwardly from the outer wall
"Wit' of the boundary
region to partially define additional thermal breaks outwardly from the
boundary region, i.e.,
between the boundary region and the external space, provides both the
additional thermal breaks
and flexibility regarding whether a cover element is used, and if used, the
design of the cover
element. Accordingly, the system herein enables the designer to have a number
of options
regarding the appearance of the installed curtain wall system.
[0064] The components of the system 20, and in particular of the mullion
assembly 54,
may be made of any suitable materials. However, it is preferred that the
thermal insulator
element is made of material or materials having low thermal conductivity
properties. For
example, suitable materials would be synthetic plastic polymers and/or
polyamide materials.
Those skilled in the art would otherwise generally be aware of suitable
materials.
[0065] It is preferred that the transverse mullion segment 49 on the
panel unit 26 is
attachable to a cooperating transverse mullion segment 49", selected to
cooperate therewith, on a
second installed panel unit 26", as will also be described (Fig. 3). As can be
seen in Figs. lA and
3, once the panel unit 26 is installed, the second installed panel unit 26" is
positioned below the
panel unit 26. The second installed panel unit 26" preferably includes a
second installed panel
48", as will also be described. As can be seen in Fig. 3, the transverse
mullion segment 49
preferably is positioned at a bottom end 68 of the panel unit 26. The
cooperating transverse
mullion segment 49" preferably is positioned at a top end 69" of the second
installed panel unit
26".
[0066] As can be seen in Figs. 1A and 3, to install the panel unit 26, it
is first moved
substantially horizontally (i.e., in the direction indicated by arrow "B" in
Figs. 1A and 3), to
engage the first mullion segment 28 of the panel unit 26 with the second
mullion segment 38' of
the first installed panel unit 26', so that the first and second mullion
segments 28, 38' are attached
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to each other to at least partially form the mullion assembly 54, as
illustrated in Fig. 5A.
However, it will be understood that when the first and second mullion segments
28, 38' are first
attached to each other, they are not horizontally aligned, because the panel
unit 26 is above the
first installed panel unit 26' at that point. Once the first mullion segment
28 and the second
mullion segment 38' are engaged, the panel unit 26 is then moved downwardly
(i.e., in the
direction indicated by arrow "C" in Figs. 1A and 3), with the first and second
mullion segments
28, 38' remaining slidably engaged, to engage the transverse mullion segment
49 at the bottom
end 68 of the panel unit 26 with the cooperating transverse mullion segment
49" at the top end
69" of the second installed panel unit 26". That is, while the first mullion
segment 28 and the
second mullion segment 38' remain slidably attached to each other, the first
mullion segment 28
is moved downwardly relative to the second mullion segment 38'. The downward
movement of
the panel unit 26 that is being installed is stopped when the transverse
mullion segment 49 at the
bottom end 68 engages the cooperating transverse mullion segment 49" at the
top end 69" of the
second installed panel unit 26".
[0067] As illustrated, the panel unit 26 preferably includes the first
mullion segment 28
on a left side 70 thereof, and the second mullion segment 38 preferably
defines a right side 71 of
the panel unit 26. However, those skilled in the art would appreciate that,
alternatively, the
second mullion segment 38 could define the left side 70 of the panel unit 26,
and the first
mullion segment 28 could define the right side 71. Those skilled in the art
would also appreciate
that any such alternative arrangement would need to be consistent with the
arrangements of the
installed panel units to which the panel unit is attached.
[0068] It can also be seen that, as illustrated in Fig. 3, the transverse
mullion segment 49
that defines the bottom end 68 of the panel unit 26 preferably is the first
transverse mullion
segment 50. In this arrangement, it will be understood that the cooperating
transverse mullion
segment 49" that cooperates with the transverse mullion segment 49 preferably
is the second
transverse mullion segment 52" (Fig. 1A). As can be seen in Figs. 1A and 3,
the cooperating
transverse mullion segment 49" defines the top end 69" of the second installed
panel unit 26". In
this arrangement, it is preferred that the top end 69 of the panel unit is
defined by the second
transverse mullion segment 52, as can be seen in Fig. 1A.
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[0069] It will be understood that, in the embodiment
illustrated in Fig. 1A, the panel unit
(not shown) that is to be installed above the panel unit 26 (i.e., with its
bottom end engaging the
top end 69 of the panel unit 26) preferably includes a transverse mullion
segment that is formed
to cooperate with the transverse mullion segment 52 positioned at the top end
69 of the panel
unit 26.
[0070] As noted above, it is preferred that the first mullion
segment 28 (i.e., included in
the panel unit 26) and the second (secured) mullion segment 38' (i.e.,
included in the installed
panel unit 26') are attachable together to form the mullion assembly 54 (Fig.
5A). The mullion
assembly 54 is for securing one or more first panels 48 in a predetermined
position relative to
one or more second installed panels 48' on the building structure 22,
positioned between the
building structure 22 and the external space 24. In one embodiment, the
mullion assembly 54
preferably includes the first mullion segment 28 of the first panel, which
includes the elongate
first main portion 30, which extends between inner and outer ends thereof 73,
74 (Fig. 2A). As
can be seen in Fig. 2A, the first mullion segment 28 preferably also includes
an elongate first
inner portion 75 attached to the first main portion 30 at the inner end 73 and
extending
substantially orthogonally from the first main portion 30, the first inner
portion 75 preferably
defining an inner aperture 76 therein. It is also preferred that the first
mullion segment 28
includes a first outer portion 77 attached to the first main portion 30 at the
outer end 74 and
extending substantially orthogonally from the first main portion 30, the first
outer portion 77
defining an outer aperture 78 therein. As can also be seen in Fig. 2A, the
first panel 48
preferably includes a first glazing unit 79 that is secured to the first outer
portion 77 and is at
least partially positioned between the external space 24 and the first outer
portion 77 when the
mullion assembly 54 is assembled (Figs. 2A, 5A).
[0071] In one embodiment, the mullion assembly 54, which is
formed when the first and
second (secured) mullion segments 28, 38' are attached to each other,
preferably also includes the
secured second mullion segment 38' of the second panel, which includes the
elongate second
main portion 40' extending between inner and outer ends 81', 82' thereof, and
an elongate second
inner portion 83' attached to the second main portion 40' at the inner end 81'
and extending
substantially orthogonally from the second main portion 40'. Preferably, the
second inner
portion 83' includes an inner peg 84' at least partially receivable in the
inner aperture 76 of the
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first inner portion 75 (Figs. 2A, 5A). The second mullion segment 38'
preferably also includes a
second outer portion 85' attached to the second main portion 40' at the outer
end 82' and
extending substantially orthogonally from the second main portion 40', the
second outer portion
85' including an outer peg 86' at least partially receivable in the outer
aperture 78. Preferably,
the second panel 48', which includes a second glazing unit 79', is secured to
the second outer
portion 85' and at least partially positioned between the external space 24
and the second outer
portion 85' (Figs 2A, 5A).
[0072] In one embodiment, it is preferred that the inner peg
84' and the outer peg 86' are
at least partially receivable in the inner and outer apertures 76, 78
respectively, to attach the first
and second inner portions 75, 83' together, and to attach the first and second
outer portions 77,
85' together respectively, so that the first and second mullion segments 28,
38' are attached to
each other, securing the first panel 48 in the predetermined position relative
to the building
structure 22, and defining the central cavity 56 (Fig. 5A) in which a central
volume of air is
isolated for at least partially thermally insulating the building structure 22
relative to the external
space 24. Preferably, the first and second outer portions 28, 38' collectively
define the boundary
region 58 between the central cavity 56 and the external space 24.
[0073] As described above, it is also preferred that the
mullion assembly 54 includes one
or more thermal insulator elements 60 at least partially positionable between
the first and second
panels 48, 48', to at least partially define the thermal breaks "U", "Z"
between the external space
24 and the boundary region 58. Those skilled in the art would appreciate that
the thermal breaks
"U", "Z" that are at least partially defined by the thermal insulator
element(s) 60 thermally
insulate between the boundary region 58 and the external space 24. As can be
seen in Fig. 5A,
the thermal breaks "U", "Z" that are at least partially defined by the thermal
insulator element(s)
60 improve the thermal insulation provided by the mullion assembly 54 overall.
[0074] Those skilled in the art would appreciate that, in the
alternative, the first mullion
segment 28 may be included in a panel that is installed on the building
structure (i.e., the panel
designated above as the "second" panel), and the second mullion segment 38'
may be included in
another panel that is to be installed on the building structure (i.e., the
panel designated above as
the "first" panel).
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[0075] It will also be understood that, in an alternative embodiment, a
panel unit may
include two first (i.e., female) mullion segments, and another panel unit
formed for engagement
therewith may include two second (i.e., male) mullion segments. Those skilled
in the art would
appreciate that these alternative embodiments of the panel units may be
desirable, depending on
the circumstances at a particular installation of the curtain wall system of
the invention.
[0076] As noted above, in one embodiment, the thermal insulator element
60 preferably
extends between the boundary region 58 and an external element that is exposed
to or engages
with the external region 24. For instance, in Fig. 5A, the external element is
the cover element
93. In that embodiment, the thermal breaks "U" and "Z" are defined between the
contact element
93 and the boundary region 58, as well as by the thermal insulator element 50.
In another
embodiment illustrated in Fig. 5B, the thermal insulator element 60 is itself
exposed to or
engages with the external region 24. As can be seen in Fig. 5B, the thermal
insulator element
60B preferably includes an external engagement portion 89B that is located at
the outer end of
the thermal insulator element 60B and is positioned between, and engaged with,
the panels 48,
48'. That is, in the absence of the cover element, the thermal breaks "UB",
"ZB" are defined by
the thermal insulator element 60B and the boundary region 58B.
[0077] As can be seen in Fig. 2A, in the embodiment illustrated, the
second mullion
segment 38' is included in the first installed panel unit 26', which is
stationary. Preferably, the
first mullion segment 28 is moved in the direction indicated by the arrow "B"
in Figs. 1A and 2A
to engage the first mullion segment 28 with the second mullion segment 38'.
[0078] It will be understood that the second mullion segment 38 defining
the right side
70 of the panel unit 26 includes elements that are the same as the elements
described above and
included in the second mullion segment 38'. For example, the second main
portion 80 of the
second mullion segment 38 is illustrated in Fig. 9A.
[0079] In an alternative embodiment of the mullion assembly 54A
illustrated in Fig. 2B,
the thermal insulator element 60 preferably is mounted in the first outer
portion 77A. It will be
understood that the first mullion segment 28A is moved in the direction
indicated in Fig. 2B by
arrows "B" to engage with, and become attached to, the second mullion segment
38A. Except
for the location of the thermal insulator element 60 on the first mullion
segment and the
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consequent changes in the outer portions 77A, 85A, the elements in Fig. 2B are
substantially the
same as the corresponding elements in Fig. 2A.
[0080] As noted above, Fig. 9A is an exploded view of certain elements of
the panel unit
26. As can be seen in Fig. 9A, the first mullion segment 28 and the second
mullion segment 38
preferably extend between respective top ends 90U, 91U and bottom ends 90L,
91L thereof. (It
will be understood that certain elements of the panel unit 26, e.g., the
panels 48U, 48L have been
omitted from Fig. 9A for clarity of illustration.)
[0081] As can be seen in Fig. 9B, when the mullion assembly 54 is
assembled, the
thermal insulator element 60 preferably extends between upper and lower ends
thereof 92U, 92L
proximal to the respective top ends and bottom ends of the attached first and
second mullion
segments 28, 38' respectively.
[0082] As noted above, the panel units 26 may be formed according to
various designs,
depending on, among other things, the overall appearance of the curtain wall
system 20 that is
sought to be achieved. In one embodiment, it is preferred that the mullion
assembly 54
additionally includes the cover element 93 that is attached to the thermal
insulator element 60.
As can be seen in Figs. 2A , 2B, and 5A, the cover element 93 preferably is
formed to engage
preselected portions of each of the first and second glazing units 48, 48'
upon the attachment of
the first and second mullion segments 28, 38' to each other to at least
partially define the thermal
breaks "U", "Z" between the external space 24 and the boundary region 58. It
can be seen in
Figs. 2A and 2B that the inner end 62 of the thermal insulator element 60 may
be secured to the
second inner portion 85' (Fig. 2A) or to the first inner portion 77 (Fig. 2B).
If the mullion
assembly 54 includes the cover element 93, then the cover element 93 may be
included in the
first mullion segment 28 or the second mullion segment 38'.
[0083] Alternatively, the mullion assembly may not include a cover
element, as noted
above. In an alternative embodiment illustrated in Fig. 5B, the mullion
assembly 54B of the
invention does not include the cover element. In this embodiment, the thermal
insulator element
60B preferably includes the external engagement portion 89B engageable with
the first and
second panels 48, 48' to at least partially define the thermal breaks "UB",
"ZB" between the
external space 24 and a boundary region 58. The external engagement portion
89B preferably is
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located at an outer end 64B of the thermal insulator element 60B. Preferably,
the external
engagement portion 89B includes wiper elements "WI3" and "WI4" for sealably
engaging the
panels 48, 48' respectively. As can be seen in Fig. 5B, at least partially due
to the wiper elements
"WI3", "WI4", the isolated air spaces "UB" and "ZB" are formed once the
mullion segments 28B,
38B' are joined together, to form the mullion assembly 54B. As can be seen in
Fig. 5B, the
mullion assembly 54B preferably is formed upon the attachment of the first and
second mullion
segments 28B, 38B' to each other. The first and second mullion segments 28B,
38B', when
attached to each other, also define a central cavity 56B in which air is
isolated, to thermally
insulate the building structure 22 relative to the external space 24.
[0084] The outer portions 77B, 85B' define the boundary region 58B
between the central
cavity 56B and the thermal insulator element 60B. In order for the thermal
insulator element
60B to provide the thermally insulative effect desired, the external
engagement portion 89B
preferably securely engages the panels 48, 48' when the segments 28B, 38B' are
attached to each
other.
[0085] Those skilled in the art would appreciate that, in addition to
practical issues
related to the engagement of the external engagement portion 89B with the
panels 48, 48', the
appearance of the external engagement portion 89B to an observer (not shown)
in the external
space may be important. Those skilled in the art would also appreciate that
the external
engagement portion 89B may be formed to have any desired appearance following
installation.
Accordingly, it can be seen from the foregoing that the mullion assembly 54B
permits the
designer to have a variety of finishes and colors and shapes in the external
engagement portion
89B.
[0086] In addition, in Fig. 5A it can be seen that, in the embodiment of
the mullion
assembly 54 illustrated therein, the corner element 93 may have a variety of
shapes and sizes.
From the foregoing, it can be seen that the system 20 of the invention can
readily be adapted to
provide a variety of designs or appearances exposed to the external space.
[0087] From the foregoing, it can also be seen that the first and second
mullion segments
28, 38' are formed to be attached together relatively easily, and the mullion
assembly 54 that
results provides good thermal insulation between the external space 54 and the
building structure
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22. In particular, the central cavity 56 provides good thermal insulation
between the boundary
region 88 and the building structure 22, and in addition, the thermal
insulator element 60
partially defines one or more thermal breaks between the external space 24 and
the boundary
region 58.
[0088] In one embodiment, the mullion assembly 54 preferably includes a
number of
additional features that result in relatively good thermal insulation
performance. Preferably, the
first outer portion 77 includes a first cavity 94 therein that encloses a
first volume of air therein
for thermally insulating the central cavity 56 relative to the external space
24 (Figs. 2A, 5A). As
can be seen in Figs. 2A, 2B, and 5B, it is also preferred that the second
outer portion 85'
additionally includes a second cavity 96 therein that encloses a second volume
of air therein for
thermally insulating the central cavity 56 relative to the external space 24.
Preferably, the first
volume of air in the first cavity 94 is at least partially isolated, so that
it thermally insulates the
central cavity 56 relative to the external space 24, to an extent. Similarly,
the second volume of
air in the second cavity 96 is also at least partially isolated.
Advantageously, because of the first
and second cavities 94, 96, the boundary region 58 in which these cavities 94,
96 are located
preferably thermally insulates the central cavity 56 relative to the external
space 24.
[0089] As can be seen in Figs. 2A and 2B, it is preferred that the inner
peg 84' has a first
side 98' with a first catch 100' thereon and a substantially linear second
side 102' opposed to the
first side 98'. Also, the inner aperture 76, in which the inner peg 84' is
receivable, is at least
partially defined by a flexible first engagement clip 104 with an aperture
catch 106 thereon
positioned to engage the first side 98' of the inner peg 84', and a flexible
second element 108
positioned to slidably engage the second side 102' of the inner peg 84'. Upon
the inner peg 84'
being inserted into the inner aperture 76 to a fully inserted position therein
(Fig. 5B), the aperture
catch 106 is engaged with the first catch 100' of the inner peg 84', to retain
the inner peg 84' in
the inner aperture 76, and the second element 106 slidably and sealably
engages the second side
102 of the inner peg 84', to provide an inner seal between the central cavity
56 and the building
structure 22. Because the aperture catch 106 on the first engagement clip 104
engages the first
catch 100' when the inner peg 84' has reached its fully inserted position, the
inner peg 84' is
thereby retained in the inner aperture 76 to partially attach the first and
second mullion segments
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28, 38' together. Such at least partial inner seal, with an at least partial
outer seal (described
below) provided by the boundary region 58, substantially isolates air in the
central cavity 56.
[0090] When the first and second mullion segments 28, 38' are attached,
the first and
second outer portions 77, 85' are secured together in a similar manner. In one
embodiment, the
outer peg 86' preferably includes an inner side 110' with an inner side catch
112' thereon and an
opposed outer side 114' with an outer wiper blade 116' mounted thereon, the
outer peg 86'
extending to an end part 118' thereof. Preferably, the outer aperture 78 is at
least partially
defined by a flexible inner engagement clip 121 with a catch 123 thereon
positioned to engage
the inner side 110' of the outer peg 85', an outer wall 125 thereof, and a
gasket 127 positioned
between the flexible engagement clip 121 and the outer wall 125 (Fig. 2A).
Although the gasket
127 preferably is a bulb gasket, it will be understood that other types of
gaskets may be used.
Upon the outer peg 86' being inserted into the outer aperture 78 to a fully
inserted position
therein (Fig. 5B), the catch 123 is engaged with the inner side catch 112' of
the outer peg 86' to
retain the outer peg 86' in the outer aperture 78, the outer wiper blade 116'
engages the outer wall
125, and the end part 118' of the outer peg 85' engages the gasket 127, to
provide at least the
outer seal between the external space and the central cavity. Such outer seal
is at least partial.
As noted above, although the inner and outer seals may be only partial, they
serve to
substantially isolate air in the thermal cavity 56, to provide a thermal break
therein.
[0091] As can be seen in Fig. 2B, the first and second outer portions
77A, 85A' differ
somewhat from the first and second outer portions 77, 85' illustrated in Fig.
2A. Each of the
outer portions 77A, 85A' preferably includes a respective cavity 94A, 96A'.
When the first and
second mullion segments are attached together to define a central cavity
therebetween, the
cavities 94A, 96A' thermally insulate the central cavity relative to the
external space 24. The
first outer portion 77A preferably includes an outer aperture 76A, and the
second outer portion
85A' preferably includes an outer peg 86A'. It will be understood that, when
the first and second
mullion segments 28A, 38A' are attached together, the elements of the outer
portions 77A, 85A'
are engaged in the same manner as the corresponding elements of the outer
portions 77, 85'.
Because the elements, and the arrangements of the elements of the outer
portions 77A, 85A' are
generally the same as the corresponding elements of the outer portions 77,
85', further
description of the elements of the outer portions 77A, 85A' is unnecessary.
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[0092] The invention preferably includes a transverse mullion assembly
129 for securing
the first panel 48 in the predetermined position relative to a second
installed panel 48" on the
building structure 22 between the building structure 22 and the external space
24. (The second
installed panel 48" is included in the second installed panel unit 26".)
[0093] It will be understood that a first transverse mullion segment 50
is included in the
first panel unit 26, which is to be installed by securing it to the second
(previously installed)
panel unit 26". It will also be understood that the panel unit 26" has
previously been secured to
the building structure 22 and to one or more other panel units. A second
transverse mullion
segment 52" is included in the second panel unit 26". As can be seen in Fig.
4B, when the first
transverse mullion segment 50 and the second transverse mullion segment 52"
are attached
together, they form the transverse mullion assembly 129. As can be seen in
Fig. 4A, in one
embodiment, the first transverse mullion segment 50 preferably is moved
substantially
downwardly (i.e., in the direction indicated by arrow "C", in Figs. 1A and 4A)
to engage the first
transverse mullion segment 50 with the second transverse mullion segment 52",
to attach the two
transverse mullion segments 50, 52" to each other, forming the transverse
mullion assembly 129.
[0094] In one embodiment, as can be seen in Figs. 4A and 4B, the first
transverse
mullion segment 50 preferably includes an elongate first main transverse
portion 131 extending
between inner and outer ends 133, 135 thereof. It is also preferred that the
first main transverse
portion 131 includes a first body segment 137 comprising first front and rear
walls 139, 141 and
one or more first side walls 143 at least partially defining a transverse
central region 145 in
which a transverse central volume of air is isolated for thermally insulating
the building structure
22 relative to the external space 24. Preferably, the first transverse mullion
segment 50 also
includes a first outer portion 147 attached to the first main transverse
portion 131 at the outer end
135 and extending substantially orthogonally from the first main transverse
portion 131. The
first outer portion 147 and the first front wall 139 preferably define a slot
149 therebetween
(Figs. 4A, 4B). In addition, the first panel 48 preferably includes the first
glazing unit 79 that is
secured to the first outer portion 147, and at least partially positioned
between the external space
24 and the first outer portion 147.
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[0095] It is also preferred that the transverse mullion assembly 129
includes the second
transverse mullion segment 52", as can be seen in Fig. 4A. Preferably, the
second transverse
mullion segment 52" includes an elongate second main transverse portion 151"
extending
between inner and outer ends thereof 153", 155". The second main transverse
portion 151"
preferably also includes a second body segment 157" with second front and rear
walls 159", 161"
and one or more second side walls 163" at least partially defining a second
central region 165" in
which a second central volume of air is isolated for thermally insulating the
building structure 22
relative to the external space 24. It is also preferred that the second
transverse mullion segment
52" includes a second outer portion 167" positioned outwardly relative to the
second central
region 165". The second transverse mullion segment 52" preferably also
includes an arm
subassembly 169" attached to the second main transverse portion 151" and
including an arm 195"
extending substantially orthogonally from a base 197" of the arm subassembly
169" secured to
the second side wall 163" of the second main transverse portion 151", the arm
195" being at least
partially receivable in the slot 149" in a secured position in which the arm
195" is sealably
engaged with the first outer portion 147" and the first front wall 139" (Fig.
4B). It is also
preferred that the second panel 48", having a second glazing unit 79", is
secured to the second
outer portion 167" and at least partially positioned between the external
space 24 and the second
outer portion 167". Preferably, the transverse mullion assembly 129 also
includes a second
gasket 199 at least partially positionable between the first and second
transverse mullion
segments 50, 52" between the arm 195" and the external space 24 when the arm
195" is in the
secured position in the slot 149" (Fig. 4B) to at least partially thermally
insulate the building
structure 22 relative to the external space 24.
[0096] It is also preferred that, when the arm 195" is in the secured
position in the slot
149", the first and second outer portions 147", 167" and the arm 195" define a
separation region
158 between the transverse central region 145 and the external space 24. The
transverse mullion
assembly 129 preferably also includes one or more transverse thermal insulator
elements 160 at
least partially positionable between the first and second panels 48, 48", to
at least partially define
one or more thermal breaks "ZTI" between the external space 24 and the
separation region 158
(Fig. 4B).
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[0097] As can be seen in Figs. 4A and 4B, the first transverse mullion
assembly 50
preferably includes a sill horizontal thermal shield "TS" that is secured to
the first transverse
outer portion 147. Preferably, the sill horizontal thermal shield "TS" is
engaged with the first
transverse outer portion 147 in a snap-fit engagement, for convenient
assembly. It is also
preferred that the gasket 199 is secured to the sill horizontal thermal shield
"TS". In one
embodiment, the gasket 199 preferably includes reglets "RG" that are securable
in slots formed
in the sill horizontal thermal shield "TS". In one embodiment, the gasket 199
preferably is
acutely angled and extends from the sill horizontal thermal shield "TS" to
engage an outer
engagement portion 188" of the base 197" when the first and second transverse
mullion segments
50, 52" are attached to each other. The gasket 199, as illustrated in Fig. 4A,
is shown as
extending from a secured end "Q" thereof that is secured to the sill
horizontal thermal shield
"TS" to an unsecured end "R" thereof that engages the outer engagement portion
188", when the
first and second transverse mullion segments 50, 52" are attached to each
other. Those skilled in
the art would appreciate that, alternatively, the gasket 199 may be secured to
the second
transverse mullion segment, so that its unsecured end engages the first
transverse outer portion
when the first and second transverse mullion segments are attached to each
other.
[0098] The sill horizontal thermal shield "TS" and the gasket 199 may be
made of any
suitable materials. It is preferred that the sill horizontal thermal shield
"TS" is made of material
or materials having low thermal conductivity properties. Preferably, the sill
horizontal thermal
shield "TS" is made of synthetic plastic polymers and/or polyamide materials.
It is also preferred
that the gasket 199 is made of suitably flexible and resilient materials. The
gasket 199 preferably
is made of EPDM (ethylene propylene diene monomer) rubber and/or silicone
rubber materials.
Those skilled in the art would otherwise generally be aware of suitable
materials.
[0099] In an alternative embodiment, illustrated in Fig. 4C, the sill
horizontal thermal
shield "TS" preferably includes an external fitting "EF" that is exposed to
the external space 24.
In this way, the same part (i.e., the sill horizontal thermal shield "TS") may
be used in
configurations in which it is not exposed (Fig. 4B) and, alternatively, in
configurations in which
it is exposed in part (Fig. 4C). It will be understood that the external
fitting "EF" may have any
suitable shape or appearance, and that wide varieties thereof are possible.
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[00100] It can also be seen in Figs. 4A and 4B that, in one
embodiment, the first
transverse mullion segment 50 preferably includes a cover element 193 that is
secured to the
thermal insulator element 160. As illustrated, the panels 48, 48" preferably
also include
respective trim elements 172 , 172".
[00101] In one embodiment, the cover element 193 preferably also
includes weep holes.
As illustrated, the cover element 193 preferably includes first and second
weep holes 180, 187.
Those skilled in the art would appreciate that the weep holes 180, 187 permit
water that has
accumulated in the panel 48 to escape therefrom, under the influence of
gravity, via a route that
is schematically indicated by line "E" in Fig. 4B.
[00102] It is preferred that the transverse mullion assembly 129
is at least partially secured
between the first and second mullion segments 28, 38 (Figs. 9A, 9B). As noted
above, the first
and second mullion segments 28,38 preferably are included in the panel unit 26
(Figs. IA, 9A).
In one embodiment, the first transverse mullion segment 50 of the transverse
mullion assembly
129 preferably is secured between the first exterior side 36 of the first
mullion segment 28 and
the second exterior side 46 of the second mullion segment 38, i.e., in the
panel unit 26 in which
the first transverse mullion segment 50 is positioned. As can be seen in Fig.
9A, in one
embodiment, the first transverse mullion segment 50 preferably is located at
the bottom end 68
of the panel unit 26. (It will be understood that the upper and lower panels
48U, 48L are omitted
from Fig. 9A for clarity of illustration.) It is also preferred that the
second transverse mullion
segment 52 (which is included in the panel unit 26) is secured between the
first exterior side 36
of the first mullion segment 28 and the second exterior side 46 of the second
mullion segment
38, i.e., in the panel unit 26 in which the second transverse mullion segment
52 is positioned. As
shown in Figs. 1A and 9A, in one embodiment, the second transverse mullion
segment 52
preferably is located at the top end 69 of the panel unit 26.
[00103] As can be seen in Fig. 4B, the first and second
transverse mullion segments 50,
52", when attached to each other, preferably are positioned so that there are
gaps therebetween,
to allow for thermal expansion of the components of the panel units. For
example, a gap formed
for this purpose in the slot 149 is identified in Fig. 4B as "G". As can be
seen in Figs. 4A and
4B, the arm 195" preferably includes seals "F" and "I" that sealably engage
the first transverse
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outer portion 147 and the first front wall 139 respectively, for thermal
insulation. It can therefore
be seen in Fig. 4B that thermal expansion and contraction of elements of the
panel units 26, 26"
can be accommodated in the transverse mullion assembly 129. For instance, if
the first and
second transverse mullion segments 50, 52" are moved toward each other due to
expansion, the
arm 195" can move further into the slot 149, and the gasket 199 can be pressed
further against
the outer engagement portion 188", while maintaining the sealed and slidable
engagement of the
seals "F" and "I" in the slot 149 and the sealed engagement of the gasket 199
and the outer
engagement portion 188".
[00104] An alternative embodiment of the transverse mullion assembly 129B
of the
invention is illustrated in Fig. 4C. In this embodiment, the transverse
mullion assembly 129B
does not include a cover element. Instead, a first transverse outer portion
147B preferably
includes a thermal insulator element 160B located between the panels 48, 48".
Otherwise, the
first and second transverse mullion segments 50B, 52B" are generally the same
as the first and
second transverse mullion segments 50, 52" respectively.
[00105] As can be seen in Figs. 1A, 9A, 9B, 10A, and 10B, in one
embodiment, the panel
unit 26 preferably includes the intermediate mullion assembly 66 for securing
the upper panel
48U and the lower panel 48L relative to the building structure 22 and located
between the
building structure 22 and the external space 24. It is preferred that the
intermediate mullion
assembly 66 includes an intermediate body 201 defining an intermediate cavity
203 therein in
which air is isolated for at least partially thermally insulating the building
structure 22 relative to
the external space 24. Preferably, the intermediate body 201 is at least
partially positioned
between the upper panel 48U and the lower panel 48L (Figs. 1A, 10B). It is
also preferred that
the intermediate mullion assembly 66 includes one or more intermediate thermal
insulator
elements 260 at least partially positionable between the upper and lower
panels 48U, 48L, to at
least partially define one or more thermal breaks "U2", "Z2" between the
external space 24 and
the intermediate body 201 (Fig. 10B).
[00106] As can be seen in Fig. 10B, the cavity 203 is partially defined by
an outer wall
285 in which a slot "SL3" is formed. Preferably, an inner end 262 of the
thermal insulator
element 260 is secured in the slot "SL3". In Fig. 10B, an outer end 264 of the
thermal insulator
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element 260 is shown as being secured to a cover element 293. It is preferred
that the cover
element 293 includes wiper elements "WI5", "WI6" that sealably engage the
panels 48U, 48L.
However, similar to alternative embodiments described above, in an alternative
embodiment, the
thermal insulator element may be formed to at least partially define the
isolated air spaces
(thermal breaks), in the absence of a cover element.
[00107] As can be seen in Fig. 10B, the air spaces "U2" and "Z2"
preferably are defined
generally between the outer wall 285 and the cover element 293, beside the
thermal insulator
element 260. The isolated air in the air spaces "U2", "Z2" provides thermal
insulation, to insulate
the isolated air in the central cavity 203 relative to the external space 24,
and therefore also
insulating the building structure 22 relative to the external space 24.
[00108] Based on the foregoing description and the drawings, it
can be seen that the
intermediate mullion assembly 66 has a structure that readily permits
adaptation thereof to
various cover elements, or alternatively, to a version with no cover element.
The thermal
insulator element 260 is part of a thermally insulating structure between the
external space 24
and the central cavity 203.
[00109] Those skilled in the art would appreciate that, when two
of the second (lower)
transverse mullion segments abut each other, it is preferred that additional
elements are used for
reinforcement, and also for alignment thereof For example, as illustrated in
Figs 11A and 11B,
a left second transverse mullion segment 452 abuts a right second transverse
mullion segment
552, i.e., after the respective panel units (not shown) in which the second
transverse mullion
segments 450, 452 are included have been installed, and are secured to the
building structure 22.
[00110] As can be seen in Fig. 11A, it is preferred that, once
the abutting transverse
mullion segments 452, 552 are in place, a silicone splice sheet 615 is located
thereon, to overlap
each of the transverse mullion segments 452. As can be seen in Figs. 11A and
11B, the left and
right second transverse mullion segments 452, 552 preferably include
respective arms 495, 595.
For the purposes hereof, the silicone splice sheet 615 is considered to be
positioned at least in
part on front sides of the arms 495, 595. As can also be seen in Fig. 11A, a
lower portion "T" of
the silicone splice sheet 615 is positioned on outer engagement portions 488,
588 of the
respective second transverse mullion segments 452, 552.
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[00111] Similarly, a reinforcing and alignment angle element 617
preferably is positioned
on the abutting transverse mullion segments 452, 552 behind (i.e., inwardly
from) the respective
arms 495, 595 of the second transverse mullion segments 452, 552. The
reinforcing and
alignment angle element 617 is illustrated in Figs. 11C and 11D. As can be
seen in Figs. 11A
and 11B, the reinforcing and alignment angle element 617 preferably is
partially secured against
rear sides of the arms 495, 595. The reinforcing and alignment angle element
617 preferably
also includes a support portion "S" that engages the base regions 497, 597.
[00112] After the silicone splice sheet 615 and the reinforcing
and alignment angle
element 617 are positioned on the left and right second transverse mullion
segments 452, 552,
the first transverse mullion segments generally corresponding thereto, that
are included in panel
units to be installed generally above the second transverse mullion segments
452, 552, are
respectively lowered onto the second transverse mullion segments 452, 552, in
the process
described above. The manner in which the silicone splice sheet 615 and the
reinforcing and
alignment angle element 617 are included in the transverse mullion assembly
429 that is formed
when the first and second transverse mullion segments 450, 452 are attached
together is
illustrated in Fig. 11E. As can be seen in Fig. 11E, the unsecured end "R" of
the gasket 599
preferably engages the silicone splice sheet 615 when the first and second
transverse mullion
segments are attached to each other.
[00113] As can be seen in Fig. 11B, in one embodiment, the
respective bases 497, 597 and
the arms 495, 595 of the respective second transverse mullion segments 452,
552 preferably
extend laterally from the respective second body segments 457, 557 thereof
toward each other.
Preferably, the arms 495, 595 abut each other at a location that is generally
in the centre of the
mullion assembly 54 (Figs. 11B, 12). As can be seen in Fig. 9A, the first main
portion 30
preferably includes a lower opening "J". It will be understood that a
corresponding opening
preferably is also formed in the second main portion 40. The opening "J"
permits the bases 497,
597 and the arms 495, 595 (and the silicone splice sheet 615 and the
reinforcing and alignment
angle element 617 engaged with the arms 495, 595) to extend into the central
cavity 56 of the
mullion assembly 54. Those skilled in the art would appreciate that connecting
the left and right
transverse mullion segments 452, 552 in this way strengthens the curtain wall
system 20.
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[00114] In one embodiment, the curtain wall system 20 of the invention
preferably also
includes one or more alignment elements "AE" that are positioned on the lower
part "S" of the
reinforcing and alignment angle element 617 to assist in the alignment of the
abutting lower
transverse mullion segments 452, 552 with each other (Fig. 12). It will be
understood that the
alignment element "AE" facilitates the alignment of an upper transverse
mullion segment upon
installation. It will also be understood that, in practice, the alignment
element "AE" appears to
be useful if used at vertical intervals, e.g., approximately once every five
transverse mullions,
counted vertically. It is believed that the use of more alignment elements
than these would
generally not be needed, in practice.
[00115] It will be understood that Fig. 10A is a cross-section of the
panel unit 26. As can
be seen in Fig. 10A, in one embodiment, the panel unit 26 preferably includes
the second
transverse mullion segment 52 positioned at the top end 69 for attachment with
a first transverse
mullion segment 50"' positioned at a bottom end 68" of a later-installed panel
unit 26".
[00116] Those skilled in the art would appreciate that, in order to begin
installation at an
extreme left- or right-hand side of an area of the building structure 22 on
which the curtain wall
system 20 is to be located, it is preferred that a jamb mullion assembly 205
(Fig. 6A) is secured
to an exposed part "X" of the building structure at a selected location
thereon. As illustrated in
Fig. 6A, the jamb mullion assembly 205 is formed to be secured to a left-hand
side of the
building structure, but those skilled in the art would appreciate that it may
alternatively be
formed for attachment to the right-hand side of the building structure. As can
be seen, for
example, in Fig. 6A, the jamb mullion assembly 205 is for securing a panel 248
in a selected
position relative to the building structure 22, between the main (unexposed)
part of the building
structure 22 and the external space 24. In one embodiment, the jamb mullion
assembly 205
preferably includes a jamb mullion body 207 defining a jamb mullion cavity 209
therein in
which air is isolated for at least partially thermally insulating the building
structure 22 relative to
the external space 24. Preferably, the panel 248 includes a glazing unit 279
that is secured to the
jamb mullion body 207 and extends from a preselected side of the jamb mullion
body 207. For
instance, as illustrated in Fig. 6A, the panel 248 and the glazing unit 279
thereof extend from the
right side of the jamb mullion body 207. It is also preferred that the jamb
mullion body 207
includes a closed side 211 thereof that is secured to the building structure
22.
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[00117] In the embodiment illustrated in Fig. 6A, a thermal
insulator element 260 is
positioned between the jamb mullion body 207 and a cover element 293. The
thermal insulator
element 260 provides a thermal break between the cover element 293 and the
jamb mullion body
207. As can also be seen in Fig. 6A, the mullion body 207 preferably also
includes walls
defining first and second cavities 294, 296 in which air is isolated, to
provide thermal insulation
between the thermal insulator element 260 and the cavity 209, to thermally
insulate the main part
of the building structure 22 relative to the external space 24.
[00118] As can be seen in Fig. 6B, in an alternative embodiment,
the jamb mullion
assembly 205B preferably includes an embodiment of the thermal insulator
element 260B of the
invention that includes an external engagement portion 289B to engage the
glazing panel 279B
and an exterior portion "Y", to thermally insulate the jamb mullion body 207B
relative to the
main part of the building structure 22.
[00119] Those skilled in the art would also appreciate that the
building design may require
additional features to be included in the curtain wall system. In one
embodiment, the mullion
assembly 354 of the invention preferably includes a bracket subassembly 313
including a base
plate "L" having opposed inner and outer surfaces "M", "N", and an outrigger
element "0"
secured to the base plate "L" and extending substantially orthogonally from
the outer surface "N"
of the base plate "L" to an end portion thereof "P" (Fig. 7A). As can be seen
in Figs. 7A and 7B,
the base plate "L" preferably is securable to the mullion body 301 (i.e.,
formed when the first and
second mullion segments 328, 338' are attached together), to locate at least a
part of the end
portion "P" extending past the panels 348, 348' and projecting into the
external space. As can be
seen in Fig. 7A, the bracket subassembly 313 preferably permits a sign or
other object to be
positioned outwardly from the panels 348, 348'. It will be understood that the
thermal insulator
element 360 preferably has a (vertical) break therein (not shown in Fig. 7A),
to accommodate the
outrigger element "0". Similarly, it will also be understood that the thermal
insulator elements
360L, 360R preferably have breaks in them also respectively, to accommodate
the outrigger
elements "LOB", "ROB" (Fig. 7B). The cover element 393 also preferably
includes one or more
notches therein (not shown) to accommodate the outrigger element "0" (Fig.
7A), and in the
embodiment illustrated in Fig. 7B, to accommodate the outrigger elements
"LOB", "ROB".
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[00120] An alternative embodiment of the mullion assembly 354B of the
invention is
illustrated in Figs. 7B and 7C, in which the mullion assembly includes two
thermal insulator
elements 360L, 360R that are positioned to provide a thermal break between the
external space
24 and the main part of the building structure 22. The mullion assembly 354B
preferably
includes a bracket assembly 313B with a base plate "LB" having opposed inner
and outer
surfaces "MB", "NB" (Fig. 7C). The bracket assembly 313B preferably includes
two outrigger
elements "LOB" and "ROB" secured to the base plate "LB". As can be seen in
Fig. 7B, the
mullion assembly 354B preferably also includes a cover element 393 to which
the thermal
insulator elements 360L, 360R are attached.
[00121] From the foregoing, it can be seen that the invention provides a
method of
securing the panel unit 26 in a predetermined position relative to the
building structure 22,
between the building structure 22 and the external space 24. In use, the
method includes
engaging the first mullion segment 28 with the substantially vertical second
mullion segment 38'
of the installed panel unit 26', to attach the first and second mullion
segments 28, 38' to each
other to form the mullion assembly 54. (It will be understood that the panel
unit 26' is secured to
the building structure 22 and to other panel units, having previously been so
secured.) The
mullion assembly 54 preferably defines the central cavity 56 therein, which is
at least partially
defined by the boundary region 58 in which the central volume of air is
isolated for at least
partially thermally insulating the building structure 22 relative to the
external space 24. The
thermal insulator element(s) 60 is (are) positioned between the boundary
region 58 and the
external space 24, for thermally insulating the building structure 22 relative
to the external space
24. While the first mullion segment 28 is attached to the second mullion
segment 38', the first
transverse mullion segment 50 is engaged with the substantially horizontal
second transverse
mullion segment 52" located on the second installed panel unit 26", to attach
the first and second
transverse mullion segments 50, 52" to each other to provide the transverse
central region 145 in
which the transverse central volume of air is substantially isolated to at
least partially insulate the
building structure 22 relative to the external space 24. The engaged first and
second transverse
mullion segments 50, 52" define the separation region 158 between the building
structure 22 and
the external space 24. The transverse thermal insulator element 160 is
positioned between the
separation region 188 and the external space 24, for thermally insulating the
building structure
22 relative to the external space 24.
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[00122] Another alternative embodiment of the mullion assembly 754 is
illustrated in Fig.
8A, in which first and second mullion segments 728, 738' support respective
thermal insulator
elements 760L, 760R. As can be seen in Fig. 8A, the thermal insulator elements
760L, 760R are
engaged between a mullion body 701 (formed by the first and second mullion
segments 728,
738') and a cover element 793.
[00123] An alternative embodiment of the mullion assembly 854 of the
invention is
illustrated in Fig. 8B. As can be seen in Fig. 8B, the mullion assembly 854
does not include a
cover element. Instead, the thermal insulator elements 860L, 860R preferably
include respective
external engagement portions 889L, 889R that engage the panels 848, 848' that
they are
positioned between.
[00124] It will be appreciated by those skilled in the art that the
invention can take many
forms, and that such forms are within the scope of the invention as claimed.
The scope of the
claims should not be limited by the preferred embodiments set forth in the
examples, but should
be given the broadest interpretation consistent with the description as a
whole.
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