Note: Descriptions are shown in the official language in which they were submitted.
CA 02950781 2016-12-07
TITLE OF INVENTION
CURTAIN WALL MULLIONS, TRANSOMS AND SYSTEMS
DESCRIPTION
BACKGROUND OF THE INVENTION
[Para 1] There are curtain wall systems or frameworks in which glazing or
other panels are fitted. Curtain walls typically comprise a grid-like
framework
usually made of aluminum profiled members arranged with transoms (i.e.,
structures that typically run horizontally) and mullions (i.e., structures
that
typically run vertically). Glazing or window panels and non-transparent panels
may be secured against the transoms and mullions. The framing is attached to
a building structure.
SUMMARY OF THE INVENTION
[Para 2] The invention pertains to a curtain wall system and separate
elements such as mullions or transoms that include a thermally insulating
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component. In some embodiments, the insulating component is a fiberglass
component such as a fiberglass reinforced polymer that is bonded to a metal
structure. The metal structure may be made of steel or aluminum for instance.
The bonding is accomplished using adhesives and/or other bonding techniques
and produces a mullion or transom having sufficient strength to support the
panels or glazing of the curtain wall. The thermally insulating fiberglass
component enhances the insulating properties of the mullions, transoms and
curtain wall system.
[Para 3] In accordance with an aspect of the invention, a steel mullion or
transom includes a stem projecting from the mullion or transom where the
stem is configured to project into a space between a first panel and a second
panel of a curtain wall. Since the stem is made of thermally insulating
material
the structure provides enhanced overall insulating properties of a resultant
curtain wall system.
[Para 4] In a further aspect of the invention, a mullion or transom for use
on a curtain wall system having at least one panel comprises a metal
structural
segment and a component made of thermally insulating material and bonded to
the metal segment, the component including a seal receiver configured to
receive a seal to be positioned between the metal segment and the panel
[Para 5] In a further aspect of the invention a curtain wall system
includes
a cell having a first mullion, a second mullion, a first transom and a second
transom, the first transom including a metal structure having a fiberglass
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component bonded to the metal structure, a panel secured to the cell, the
fiberglass component including a stem configured to support a weight of the
panel.
[Para 61 In a further aspect the invention includes a method of making a
component by pultruding a fiberglass to have a profile configured to cover an
entirety of an outside of a mullion or transom of a curtain wall and to have a
pair of receivers for receiving seals to abut against panels of the curtain
wall.
Further profiles are contemplated under the methods of making components by
pultrusion.
[Para 7] In a further aspect of the invention a metal curtain wall mullion
or
transom has an outer side and a component connected to the outer side by a
first fastener passing through the outer side and into the component. The
fastener is inserted from the inside-out, i.e., from the inside of the metal
structure, through the outer side, and into the component.
[Para 8] The above partial summary of the present invention is not
intended to describe each illustrated embodiment, aspect, or every
implementation of the present invention. The figures and detailed description
and claims that follow more particularly exemplify these and other
embodiments and further aspects of the invention.
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BRIEF DESCRIPTION OF THE DRAWINGS
[Para 91 The invention may be more completely understood in
consideration of the following description of various embodiments of the
invention in connection with the accompanying drawings, in which:
[Para 1 0] Figure 1 is a front view of a cell of a curtain wall system
according
to some embodiments of the present invention.
[Para 1 1] Figure 2 is a sectional view of a mullion along line 2-2 of
Figure
1, according to some embodiments.
[Para 1 2] Figure 3A is a sectional view of a transom along line 3-3 of
Figure 1, according to some embodiments.
[Para 1 3] Figure 3B is a sectional view of a transom along line 3-3 of an
alternative aspect of Figure 1, according to some embodiments.
[Para 1 4] Figure 3C is a sectional view of a transom along line 3-3 of an
alternative aspect of Figure 1, according to some embodiments.
[Para 1 5] Figure 3D is a sectional view of a transom positioned along a
bottom wall of an alternative aspect of Figure 1, according to some
embodiments.
[Para 1 6] Figure 4 is a sectional view of a mullion along line 2-2 of
Figure
1, according to some further embodiments involving use of aluminum.
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[Para 17] Figure 5 is a sectional view of a transom along line 3-3 of
Figure
1, according to some further embodiments involving use of aluminum.
[Para 18] Figure 6 is a sectional view of a mullion along line 2-2 of
Figure
1, according to some further embodiments.
[Para 19] Figure 7 is a sectional view of a transom along line 3-3 of
Figure
1, according to some further embodiments.
[Para 20] Figure 8 is a sectional view of a mullion along line 2-2 of
Figure
1, according to some further embodiments.
[Para 21] Figure 9 is a sectional view of a mullion along line 2-2 of
Figure
1, according to some further embodiments.
[Para 22] Figure 10 is a sectional view of a mullion positioned along an
end
wall of Figure 1, according to some further embodiments.
[Para 23] Figure 11 is a section view of a transom according to some
further embodiments.
[Para 24] Figure 12 is a sectional view of a transom according to some
further embodiments.
[Para 25] Figure 13 is a section view of a mullion according to some
further
embodiments.
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[Para 26] Figure 14 is a section view of a mullion according to some
further
embodiments.
[Para 27] Figure 15 is a section view of a mullion according to some
further
embodiments.
[Para 28] Figure 16 is a section view of a mullion according to some
further
embodiments.
[Para 29] Figure 17 is a section view of a transom according to some
further embodiments.
[Para 30] While the invention is amenable to various modifications and
alternative forms, specifics thereof have been shown by way of example in the
drawings and will be described in detail. It should be understood, however,
that the intention is not necessarily to limit the invention to the particular
embodiments, aspects and features described. On the contrary, the intention is
to cover all modifications, equivalents, and alternatives falling within the
spirit
and scope of the invention and as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[Para 31] Figure 1 is a front view of a cell 20 of a curtain wall system 22
according to some embodiments. System 22 is shown in partial (and panels are
not shown). It may be appreciated that multiple cells 20 may comprise system
22. Figure 2 is a sectional view of a mullion 24 of cell 20. Figure 3 is a
sectional view of a transom 26 of cell 20. A similar transom 26' is positioned
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generally parallel with transom 26. A similar mullion 24' is positioned
generally
parallel with mullion 24. Together mullions 24, 24' and transoms 26, 26'
comprise a single cell 20 of curtain wall system 22. It may be appreciated
that
mullions 24 and transoms 26 also comprise additional cells 20' or components
of cells 20' of system 22. It may be appreciated that panels such as windows,
glass, or plates or other objects may be inserted within a cell 20 to cover or
span the space, light or opening created by mullions 24 and transoms 26.
[Para 32] As
shown in Figure 2, mullion 24 includes a first mullion segment
30. In some embodiments mullion 24 includes a second mullion segment 32
and a third mullion segment 34. Mullion segments 30, 32 and 34 form a
mullion 24 and define a mullion cavity 29. In some embodiments mullion 24 is
made of steel. Particularly, segments 30, 32 and 34 may be made of steel. In
one example, segments 30, 32 and 34 may be formed by bending 12 gage
steel sheets. In one aspect mullion 24 includes a polymer component 40 which
is bonded to mullion 24. Polymer component 40 is formed of a thermally
insulating material. In one aspect polymer component 40 is made of fiberglass
reinforced polymer (FRP) or glass-fiber reinforced polymer (GFRP) which in one
example is a fiber reinforced polymer including plastic. A variety of glass,
fiberglass and/or plastics may be used. In one aspect polymer component 40
is made of material including fiberglass and polyester, or fiberglass and
vinyl
ester, or fiberglass and polymers, and may include non-fire retardant
materials
or fire retardant materials. Polymer component 40 may be made using a
pultrusion process and may include reinforcing structures or mats to provide
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structural support. Rovings may be located in the component 40 which may
also include an external coating or coatings. Polymer component 40 thus has
favorable insulating features. In one aspect involving steel structural
segments
30, 32 and 34, polymer component 40 fills a gap that would otherwise lead
from outer side 25 to cavity 29.
[Para 33] In one aspect polymer component 40 is bonded to mullion 24
with an adhesive. A variety of bonding ingredients and techniques may be used
to secure polymer component 40 to mullion 24. As shown in one aspect,
polymer component 40 includes an interlock 42 which is configured to receive
tail 31 of first mullion segment 30. Tail 31 may be both friction fit within
interlock 42 and also bonded within interlock 42 with an adhesive and/or
bonding treatments. In one aspect interlock 42 is a gap defined by polymer
component 40. Polymer component 40 may include a lip 43 which in part
defines interlock 42 as shown. Polymer component 40 also includes a first
arm 44 having a tail-contact surface 45 which is bonded to the outside surface
of tail 31. In one aspect, tail contact surface 45 covers the entire area of
the
outside surface of tail 31. In this manner tail 31 is not exposed to the
outside
element which would otherwise tend to corrode or deteriorate tail 31. Polymer
component 40 also includes a second arm 46 having a tail contact surface 47
which in one aspect may be bonded to the outside surface of tail 33 of third
mullion segment 34. In one aspect tail contact surface 47 may cover the
entirety of the outside surface of tail 33. It may be appreciated that contact
surface 47 may also cover less than the entirety of the outside surface of
tail
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33. Polymer component 40 may also include a further lip 48 configured to
adhere to tail 33. In further aspects arm 46 may loosely fit against tail 33
(i.e.,
not be bonded) so that arm 46 may slide with respect to tail 33. Likewise, lip
48 may also be a loose fit against tail 33. It may be appreciated that
alternative
configurations of polymer component 40 may be used to assist in adhering
polymer component 40 to mullion 24 (whether adhering to segment 30, 32 or
34). Polymer component 40 is configured to adhere to mullion 24 while also
having a stem portion 80 extending between or into a gap or pocket defined in
part by panels 50, 50'. A fastener 39 may insert through a pressure plate 36
and into the stem to secure panels 50, 50' in position. Seals 60, 60 may be
positioned between pressure plate 36 and panel frame 52. A cover plate 38
may be positioned to cover pressure plate 36. It may be appreciated that panel
50 may be positioned within cell 20 while panel 50' may be positioned within
an adjacent cell 20'.
[Para 34] In a
further aspect polymer component 40 includes a seal receiver
49 configured to receive a seal 60. In one aspect seal receiver is defined by
seal fingers 41. Seal 60 is configured to insert into seal receiver 49 and
between first arm 44 and panel frame 52. Seal 60 may fiction fit to panel
frame
52 and may also be bonded to panel frame 52. Seal 60 may be of a
conventional variety used in curtain wall systems. Seal 60 may also include a
wrap segment 62 to partially cover an edge of first arm 44. In a further
aspect
polymer component 40 includes a further seal receiver 49 positioned at or
defined by second arm 46. In one aspect seal receiver 49 may be configured to
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receive a seal 66 configured to interact with a shoulder 70 described below.
In
one aspect seal 66 is positioned between second mullion segment 32 and third
mullion segment 34.
[Para 35] As shown in Figure 2 mullion 24 includes a shoulder 70
connected to second mullion segment 32. In one aspect shoulder 70 includes
an interlock 42'. Interlock 42' is configured to receive tail 35 of segment
32.
Tail 35 may friction fit within interlock 42' and/or be bonded to shoulder 70
within interlock 42'. Shoulder 70 is made from the same or similar material as
is polymer component 40 described above. In one aspect shoulder 70 abuts
polymer component 40. A sealant 64 may be applied where shoulder 70 meets
polymer component 40. In a further aspect shoulder 70 includes a seal receiver
49'. Receiver 49' is configured to receive a seal 60. In one aspect seal
receiver
49' is defined by seal fingers 41. Seal 60 is configured to insert into seal
receiver 49' and between shoulder 70 and panel frame 52. Seal 60 may friction
fit to panel frame 52. Seal 60 may be of a conventional variety used in
curtain
wall systems. Panel frame 52 may also be secured to seal 60 with an adhesive.
Seal 60 may also include a wrap segment 62 to partially cover an edge of
shoulder 70. In a further aspect shoulder 70 may be configured without elbow
71 (i.e., elbow extends from shoulder 70 at line "e" as shown in Figure 2).
Tail
35 may extend further toward tail 31 to lessen a gap there between. Shoulder
70 may friction fit or interlock and/or bond to tail 35.
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[Para 36] It may be appreciated that polymer component 40 and shoulder
70 combine to cover the entirety of the outer side 25 of mullion 24.
Particularly, polymer component 40 and shoulder 70 are configured such that
no portion of mullion 24 is exposed to outer side 25, nor is any segment of
mullion 24 in communication with the panels 50, 50' or the pocket 28 between
panels 50, 50'. Maintaining the segments of mullion 24 in isolation from the
outside atmosphere improves the insulating characteristics of system 22.
[Para 371 As shown, mullion 24 is a composite structure made of steel
segments 30, 32, 34 to which the fiberglass items, such as polymer component
40 and shoulder 70 are bonded or laminated. Polymer component 40 and
shoulder 70 are configured to remain connected to mullion 24. In one aspect
polymer component 40 and shoulder 70 are continuous in that they span the
length of mullion 24.
[Para 38] As shown in Figure 3A, transom 26 (i.e., a horizontally oriented
element of cell 20) includes polymer component 140 which is made of material
that is the same or similar to the material used to make polymer component 40
referenced above. Polymer component 140 includes a first arm 144 having a
transom contact surface 145 and a second arm 146 having a transom contact
surface 147. In one example component 140 is bonded to transom 26 at least
at contact surfaces 145, 147. Particularly, first arm 144 and second arm 146
may be bonded with an adhesive and other bonding techniques to transom wall
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130. Wall 130 is formed of metal and in one aspect is formed of steel and in
one aspect is bent into configuration.
[Para 39] As
shown in Figure 3A, wall 130 includes receiving arm 131, 131'.
In one aspect arm 131 is integrally connected to wall 130 and is configured to
receive contact surface 145. Receiving arm 131 may be bent into position as
shown for instance in Figure 3 and then welded to transom plate 58 at weld 56.
In one aspect receiving arm 131 leads to receiving hand 132 and hand 132 is in
turn welded to transom plate 58 with weld 56. It may be appreciated that hand
132' may be oriented parallel or at least substantially parallel with hand
132.
As such, hand 132 and hand 132' are opposing walls. Polymer component 140
further includes fingers 141a, 141b configured to bond with wall 130. In one
aspect finger 141a is bonded to hand 132 and finger 141b is bonded to hand
132'. An adhesive may be applied between polymer component 140 and wall
130 to securely bond component 140 along an entirety of the exterior surface
of arm 131 and continuing about the curve 133 and along hand 132. Likewise
an adhesive may be applied to securely bond component 140 along an entirety
of the exterior surface of arm 131' and continuing about the curve and along
hand 132'. It may be appreciated that the combination of adhesive and the
structural matching arrangement of fingers 141 combine to provide a secure
bond sufficient to allow component 140 to withstand the forces associated with
bearing the weight of panels 50, 50' and other forces associated with or
applied
to the panels.
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[Para 40] Fingers 141a, 141b also allow for efficient alignment of
component 140 onto wall 130. Fingers 141 are positioned on component 140
to match the gap between hands 132, 132' and to also receive an adhesive
between component 140 and wall 130. Wall 130 is bent with corners 133 to
match the contour of finger 141a (and/or vice versa) and the same is presented
with finger 141b and at a distance to match the gap between hands 132, 132',
to provide a secure bond. A variety of steps for preparing the surfaces and/or
curing or treating the adhesives, as needed, may be used to achieve a secure
bond of component 140 to wall 130. It may be appreciated that fingers 141
may be positioned in different locations, and in some applications may be
reconfigured into different shapes/dimension and/or removed altogether.
[Para 41] It may be appreciated that polymer component 140 covers the
entirety of outer side 125 of transom 26. Such configuration assures that no
portion of transom 26 is in communication with the exterior atmosphere or
panels 50, 50' or the pocket 28 between panels 50, 50'. Maintaining such
isolation improves the insulating characteristics of system 22.
[Para 42] In a further aspect polymer component 140 includes a seal
receiver 149. Receiver 149 is configured to receive a gasket or seal 60. In
one
aspect seal receiver is defined by seal fingers 41. Seal 60 is configured to
insert into seal receiver 149 and between component 40, 140, and panel frame
52, i.e., between first arm 144 and panel frame 52. Seal 60 may be bonded to
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panel frame 52. Seal 60 may be of a conventional variety used in curtain wall
systems.
[Para 43] In one aspect a pressure plate 36 is fastened with a screw 39 to
stem 80 of component 140 and applies pressure to seals 60 which in turn apply
pressure to panels 50, 50' and against component 140. It may be appreciated
that a setting block may be positioned between stem 80 and panel 50. It may
be appreciated that component 140 together with pressure plate 36 secure
panels 50, 50' to transom 26.
[Para 44] In a further aspect the stem 80 includes a groove 82 configured
to receive a fastener 39 (see also Figure 3B). Groove 82 may include a taper
84
to assist in receiving fastener 39. Groove 82 may be a continuous groove which
spans the length of component 40, 140. It may be appreciated that groove 82
operates as a pilot hole to receive and contain fastener 39. In one aspect
groove 82 is configured to securely receive a fastener such as a screw,
including a #14 stainless steel HWH SMS screw. A plurality of screws 39 may be
inserted along transom to secure a plurality of panels 50, 50' into position.
In
one instance screws 39 may be positioned at 9 inches on center. Other
arrangements may be used as desired.
[Para 45] Figure 3B shows a further aspect of transom 26 having a
symmetrically disposed polymer component 140. Also shown is a setting block
37 positioned between component 140, particularly, between the stem 80 of
component 40, and a panel 50. In one example setting block 37 is a silicone
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block of about 4 inches to 6 inches in length. Block 37 may also be a
continuous length to match the length of transom 26 or in other examples may
be a shorter length. Block 37 may include a block tip 37a which is a
projection
from block 37 configured to abut component 40 for appropriate spacing of
block 37 beneath panel 50 within pocket 128. In one example a number of
setting blocks 37 may be used and staggered at various locations along the
system 22. Blocks 37 may be positioned at quarter points along panel 50, for
example. Block 37 or blocks 37 allow for the weight of a panel 50 to be
transferred to the stem 80 or polymer component 40. Use of blocks 37 may
also be employed with reference to Figure 5 and Figure 7. In this manner the
weight of panels 50 is supported by polymer component 40. Pressure plate 36,
which is secured to polymer component 40 by a fastener 39, for instance,
applies pressure to seals 60, 60, which in turn apply pressure to panels
50,50'.
In one aspect seal 60 may include, for instance, a 60 durometer silicone
gasket.
The interior side seal 60 may include a lineal or molded corner configuration
for instance. Pressure plate 36 may also include a weep hole 51 which is an
aperture defined by plate 36. Weep hole 51 allows for moisture to escape from
pocket 128. A gasket, such as gasket 53 may be positioned between pressure
plate 36 and stem 80. Gasket 53 may include a silicone material, such as a 70
durometer silicone gasket separator. It may be appreciated that polymer
component 40 extends into pocket 128 between panels 50, 50'. Pressure plate
36 may extend a length of transom 26. Pressure plate 36 may include several
weep holes 51 spaced at various positions along the length of plate 36. In one
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example weep hole 51 may be positioned on pressure plate 36 at a position
above polymer component 40 as shown. This allows water or moisture to
escape from below panel 50.
[Para 46] Figure 3C shows a further aspect of transom 26 having a
symmetrically disposed polymer component 140. In this aspect the transom 26
includes a glazing tape 54 between panel 50 and component 40. In one aspect
glazing tape 54 is a two sided glazing tape. Use of glazing tape 54 secures
panel to polymer component 40 which is in turn secured to transom wall 130.
In addition, a silicone layer 68 such as structural silicone is also
positioned
between panel 50 and component 40. Together the glazing tape 54 and
structural silicone 68 secure panel to transom 26 while also maintaining a
seal
relationship. A silicone gasket 69 is positioned at an edge of component 40
and structural silicone 68 for additional insulation and/or for cosmetic
purposes to conceal the structure. Gasket 69 inserts into a gasket receiver
69'
of component 40. A similar arrangement may also be used to secure panel 50'
to transom 26. It may be appreciated that use of glazing tape 54 and
structural
silicone 68, for instance, allows for securing panel 50 to transom 26 without
the use of a fastener such as shown the Figure 3A or Figure 3B. A sealant 64
may be applied between panels 50, 50', for instance, and/or applied to stem 80
of component 40. A setting block 37 may also be used to receive panel 50.
[Para 47] Figure 3D shows a further aspect of transom 26 having a
symmetrically disposed polymer component 40 and where the transom 26 is
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positioned adjacent a horizontal (such as at a bottom area of a curtain wall
system). A single (upper) panel 50 is used in this aspect. A PVC spacer 67 is
positioned between pressure plate 36 and component 40. A sealant 64 and
seal 60 may be positioned between the horizontal and cover plate 38 and at the
joint of component 40 and transom wall 130. A setting block 37 may be used
to set transom 26.
[Para 48] As shown in Figure 4, a further aspect of the invention is shown
where mullion 224 is made of aluminum. Mullion 224 is made of a first mullion
segment 230 and a second mullion segment 232. A polymer component 240 is
bonded to mullion 224. In one aspect polymer component 240 is bonded, by
an adhesive and other bonding techniques, to segment 230. Polymer
component 240 may include an interlock 242 to receive a mullion finger of
segment 230. Interlock 242 in one aspect is configured as part of first arm
244. First arm 244 may include a lip 243 which inserts into a gap defined by
segment 230. Adhesive is applied to the surfaces to bond first arm 244 to
segment 230. Bonding treatments and procedures are used to assure a rigid
connection. In one aspect contact surface 245 is bonded to segment 230.
Polymer component 240 further includes seal receiver 249. Receiver 249 is
configured to receive a seal 60. In one aspect seal receiver is defined by
seal
fingers 241. Seal 60 is configured to insert into seal receiver 249 and
between
first arm 244 and panel frame 52. Seal 60 may be bonded to panel frame 52.
Seal 60 may be of a conventional variety used in curtain wall systems.
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[Para 49] As shown in Figure 4, transom 224 further includes shoulder 270
laminated or bonded to mullion 224. Particularly shoulder 270 is rigidly
connected to segment 232. Shoulder 270 includes interlock 242 which may be
the same or similar to interlock 242 defined by polymer component 240.
Segment 232 may also include tail 231 which may be friction fit and/or bonded
within gap formed by lip 243. Shoulder 270 abuts polymer component 240 and
may include seal 264. Shoulder 270 may further include seal receiver 249 to
receive seal 60. Shoulder 270 and polymer component 240 are bonded to
mullion 224 at outer side 225 and prevent mullion 224 from communication
with panels 50, 50' or pocket 228.
[Para 50] With reference to Figure 5, a further aspect of transom 326 is
shown which includes transom wall 330. Polymer component 340 is bonded to
transom 326. Polymer component 340 is made of the same or similar material
as is the polymer component 40 noted above. Polymer component 340 is
configured to friction fit and/or bond with or to outer side 335 of transom
326.
In one aspect polymer component 340 includes a lip 343 which inserts into a
gap formed in part by tail 331 of transom wall 330. Transom 326 may be made
of aluminum and may be extruded, for instance. Lip 343 and tail 331 create an
interlock 342. Polymer component 340 further includes a first arm 344 which
includes a seal receiver 349. Receiver 349 is configured to receive a seal 60.
In
one aspect seal receiver is defined by seal fingers 341. Seal 60 is configured
to
insert into seal receiver 349 and between first arm 344 and panel frame 52.
Seal 60 may be bonded to panel frame 52. Seal 60 may be of a conventional
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variety used in curtain wall systems. Polymer component 340 in this aspect
completely covers outer side 325 of transom 326.
[Para 51] With reference to Figure 6, an alternative mullion 24 which is
similar to the mullion 24 of figure 2 further includes a fastener 72 such as a
screw. Fastener 72 includes additional support to further inhibit separation
of
polymer component 40 from mullion 24. In one aspect fastener 72 is
positioned through first arm 44 of polymer component 40 and through tail 31
of steel segment 30. A sealant may also be inserted to cover the head of
fastener 72 and to seal the opening (or edges of the opening) which is created
by fastener 72. Use of fastener 72 provides enhanced protection in the event
of
a fire situation where temperatures can be extreme. It is envisioned that the
bonding of polymer component 40 (and shoulder 70) will withstand very high
temperatures without separation and/or with use of fastener 72 such
separation will be inhibited or prevented. Polymer component 40 is made of
fire retardant material. Accordingly, the features presented in Figure 6
provide
a mullion with an enhanced fire rating.
[Para 52] Figure 7 shows transom 26 where fastener 72 is inserted through
polymer component 140 where polymer component 140 is also bonded to
transom 26. This arrangement has similar separation inhibiting aspect as
noted with Figure 6.
[Para 531 Figure 8 shows a polymer component 40 bonded to mullion 24.
In this aspect mullion includes first mullion segment 30 having a tail 31a
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leading to arm 31b and hand 31c. Arm 31b extends from tail 31a in a
generally perpendicular orientation. Hand 31c extends from arm 31b in a
generally perpendicular orientation. Component 40 is bonded to segment 30 at
tail 31a, arm 31b and hand 31c. Mullion 24 also includes second mullion
segment 32 which includes shoulder polymer component 70. Component 70 is
made of the same or similar material as component 40. Component 70 is
bonded to segment 32 at tail 35. It may be appreciated that the exterior
surface of tail 35 is covered from the atmosphere or from communication with
panel 50' or pocket 128. It may also be appreciated that the exterior surface
of
segment 30, such as at tail 31a, arm 31b and hand 31c, is also covered from
the atmosphere or from communication with panel 50 or pocket 128.
Component 70 may wrap at least in part at a tip of tail 35. Component 40 and
component 70 include seal receiver 49, 49' to receive respective seals 60.
[Para 54] Figure 9 shows a polymer component 40 and a polymer
component 70 bonded to mullion 24. The bonding is achieved by use of an
adhesive applied. In this aspect component 40 is devoid of a stem and does
not include an element which projects into pocket 128. Panels 50, 50' are
secured to component 40 and component 70, respectively, with glazing tape 54
and structural silicone 68. A sealant 64 and seal 60 are applied between
panels
50, 50'.
[Para 55] Figure 10 shows a polymer component 40 bonded to mullion 24.
In one aspect mullion 24 is formed of bent sheet steel. In this view mullion
24
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is positioned adjacent or against a vertical wall and connects with a transom
26
having wall 130. Transom 26 also includes an end plate 135 welded at an end
of transom 26. End plate 135 receives fasteners which pass through mullion
24. A single segment mullion 24 is configured with opposing walls 132, 132'
to accommodate adherence of fingers 141a, 141b. Segment 40 is bonded to
mullion 24 as noted above with respect to the further aspects. Segment 40
includes seal receivers 49, 49' to receive a seal 60 and/or a PVC spacer 67.
It
may be appreciated that an entirety of an outside surface of mullion 24 is
isolated from the atmosphere or from communication with panel 50' and/or
pocket 128. It may be appreciated that panel 50' may also be fastened to
mullion 24 by use of glazing tape and silicone gasket as desired (and as an
alternative to use of a fastener and/or stem 80).
[Para 56] While there are some curtain wall systems made of metal, most
are made of aluminum. Some curtain wall installers may not appreciate the
difficulties in working with steel systems due to the need to assure non-
exposure of parts to the atmosphere or water which would otherwise result in
deterioration, or for other reasons (or if they do, the exactness of the
installation may require extra time and expense to complete the project). A
tradesman accustom to installing aluminum systems might be more apt to
make a mistake in dealing with steel, or if a mistake is made, the resulting
damage is, or can be, much more significant as compared to a mistake in
installing an aluminum system.
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[Para 57] Accordingly, use of a system where the fiberglass reinforced
polymer elements act as the stem and/or cover the face side of mullion 24 (or
transom 26) is desired. It would not matter if an installer would be concerned
about confronting a steel mullion structure as opposed to an aluminum
structure since either may be configured to prevent exposure of the frame
element (while also providing improved insulating aspects).
[Para 58] Mullion 24 may be of varying lengths depending on the desired
application. In one example, mullion 24, and thus segment 30 may have a
length of up to 24 feet, or at least 24 feet. A press that is 24 feet long, or
at
least 24 feet long may be used to form mullion 24 at such length. Mullion 24
may also be of smaller length as desired and smaller presses and tooling may
also be used. Mullion 24 may be formed at a variety of widths. In one example
mullion 24 may vary in width from 1 3/4 inches (45 mm), for instance, to 4
inches (100mm) or more, and may vary in depth from 4 inches (100 mm), for
instance, up to 16 inches (405mm) or more. Different lengths, widths and
depths and other dimensions may also be used as desired.
[Para 591 All of such variously dimensioned mullions and transoms and
individual segments can be manufactured using the same tooling and break
press machine in a bending process. In another example mullion and transom
may be manufactured using a roll forming technique. In a roll forming
technique different tooling would be used to manufacture mullions or transoms
having different dimensions. By utilizing the same break press machine and
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tooling, however, a variety of dimensions with custom or various profiles may
be formed at lower cost. Steel cannot be extruded, or is extremely difficult
or
impossible to extrude with present or typical machinery or methods. Bending
of steel is used to provide the profile as shown in the Figures, for example.
[Para 60] The
bending of steel by use of a press brake and tooling to make
curtain wall components or segments as presented at such lengths and
tolerances has heretofore never been done before or even appreciated as being
capable of accomplishment (despite a long-felt need in the market). This is
remarkable especially due to the complexities, uncertainties and difficulties
given the need for particular tolerances and lengths of products and
equipment, together with the difficulties in handling the products and the
precise nature required for creating the products and associated equipment.
Until the present invention there has been a lack of appreciation of the
opportunity to utilize press-brake bending of steel for creating curtain wall
segments. Press break bending has not been utilized for creating curtain wall
products having lengths of 24 feet, or even greater than 20 feet. Applicant
appreciates the difficulty in obtaining or maintaining required tolerances
along
the entire length of the segments, for instance, the need to have clean or
complete folds or bends (which also avoid facture or cracking during forming)
that run uniformly along the entire profile length of the lengthened steel
products. An added benefit of using a press brake forming process under the
invention is that the steel curtain wall segments may be customized to
accommodate different depths or other dimensions (while still maintaining
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desired tolerances and long lengths) without having to purchase or design new
equipment or tooling.
[Para 61] A method aspect of the invention includes bending sheets of steel
to make a variety of curtain wall mullion or transom segments and bonding a
fiber reinforced polymer element to the structure such that the bonded element
extends into a gap defined by two adjacent panels supported by the system.
The method includes using a press brake and a set of tooling elements
configured for use in conjunction with the press brake to bend a sheet of
steel
to form a first mullion segment. The bonded segment has a polymer
component. The method further includes using the press brake and at least
some of the same tooling elements (or all of the same tooling elements) to
bend a second sheet of steel to form a second mullion segment. The bonding
process may include use of adhesives and curing agents and application of
temperature or other bonding techniques to assure a rigid formation of the
polymer component to the mullion or transom structure.
[Para 62] A further aspect of the invention includes a method of making a
thermally insulating component configured to be bonded to a metal structure
where the method comprises pultruding the component with a thermally
insulating material through a pultrusion die having a profile perpendicular to
the direction of pultrusion including a stem 80 extending in a first direction
from a base 81, first arm 144 and second arm 146 extending from opposite
sided of base 81 and each extending perpendicular to the stem 80 and each
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defining a seal receiver 149 having an opening toward the first direction. In
a
further aspect the stem 80 includes a groove 82 configured to receive a
fastener 39. Groove 82 may include a taper 84 to assist in receiving fastener
39. Groove 82 may be a continuous groove which spans the length of
component 40, 140. It may be appreciated that groove 82 operates as a pilot
hole to receive and contain fastener 39. In one aspect groove 82 is configured
to securely receive a fastener such as a screw, including a #14 stainless
steel
HWH SMS screw. In a further aspect the component profile includes a first
finger 141a and a second finger 141b each extending from base 81 opposite
stem 80. Fingers 141 are configured to align with a curve of metal structure
26, and particularly configured to conform to opposing hands 132, 132'. While
other arrangements are available, in one aspect fingers 141 are symmetrically
separated by a distance greater than the width "w" of stem 80. The thermally
insulating component 40 may be pultruded from fiberglass material, and may
also include reinforcing mats and an exterior surface may include a heat set
resin coating. In further aspects the invention includes the method of
pultruding the various thermally insulating components 40, 140 (and
components 70, 170, 270) as described herein.
[Para 63] A
further aspect of the invention includes a method of bonding a
thermally insulating component to a metal structure. The metal may include
steel, aluminum, alloys or other metals. In one aspect the method includes
providing an adhesive between a pultruded fiberglass material and an outer
side 125 of metal structure 26. In one aspect the fiberglass material is a
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polymer component 40 having fingers 140 that fit with respective hands 132 of
the metal structure 26. In further aspects the method includes bonding the
component 40 to the cover the entirety of the outer side 125 of metal
structure
26.
[Para 64] Figure 11 is a section view showing a further aspect of the
invention. Transom 426 is a metal structure and includes a metal first segment
430 and a metal second segment 432 connected thereto. Segments 430, 432
may be made of extruded metal such as aluminum. Segment 432 may snap-fit
into connected position. Transom 426 has an outer side 433 which is oriented
toward or facing panels 50 or an outside of the building to which transom 426
is connected. Segment 430 includes an access port 434 such that when
segment 432 is not connected to segment 430, access is made available to
inside 435 of transom 426. Particularly, access may be made through port 434
such that a fastener 39 may be inserted into and through segment 430.
Fastener 39 may be inserted such that a head 39a of fastener 39 abuts inner
surface 436 of transom 426. In one aspect fastener 39 is inserted through
segment 430 to outer side 433 of transom 426.
[Para 65] Transom 426 includes a component 440 connected to transom
426 at outer side 433. Component 440 may be made of materials noted above
regarding components 40, 140. In one aspect component 440 includes a head
442 which inserts into a pocket 438 of segment 430. Head 442 may include
ear or ears 444 which in one aspect insert into interlocking slots 445 defined
at
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least in part by pocket rib 446. Component 440 also includes shoulder 448 or
opposing shoulders 448 which abut transom 426 at outer side 433.
Particularly, shoulder 448 abuts and covers outer side face 433' of segment
430. It may be appreciated that component 440 abuts and covers the entirety
or substantially the entirety of outer side 433 of segment 430. Covering the
entirety of outer side 433 isolates the metal transom 426 from the outside and
insulates transom 426. Component 440 also defines a bore such as head bore
450 which is configured to receive fastener 39. Head bore 450 opens toward
head 442 such that fastener 39 penetrates through segment 430 and into bore
450. Bore 450 is a closed bore in that bore 450 is closed opposite head 442
(i.e., the bore does not run through the component). In this manner component
440 may be fastened to transom 426 without exposing any part of transom or
outer side 433 to the elements. There are no perforations made through
component 440 which would otherwise tend to cause moisture or cold or
outside air to contact transom 426. Bore 450 also allows for efficient
insertion
or securing of fastener 39 to component 440. Given the nature of the materials
used to make component 440, such as in one instance component 440 is made
of reinforced fiberglass, bore 450 allows the fastener 39 to penetrate or
connect to component 440 without undue trauma to component 440. The
absence of bore 450 might otherwise cause component 440 to splinter or crack
or otherwise become weak when fastener 39 is inserted. In one instance
fastener 39 includes self-threading threads which impart corresponding thread
grooves in component 440 at bore 450. Opposite from bore 450 is stem bore
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452 defined by stem 480. Bore 452 receives a fastener 39. Fastener 39 may
secure pressure plate to transom 426. Bore 452 opens outward and has a
closed end or bottom oriented toward segment 430. Shoulder 448 may include
a seal receiver 49 to receive a seal 60. Seal 60 abuts panel 50. A spacer or
setting block 37 is positioned on component 440 at stem 480. Upon block 37
rests panel 50. It may be appreciated that panel 50 will have a weight and the
weight is supported by component 440. Component 440 extends between or
into a gap between panels 50, 50. In this manner component 440 is a
structural support of panel 50. It may be appreciated that component 440 may
extend the entire length or substantially the entire length of the face or
outer
side 433 of segment 430.
[Para 66] In one
aspect component 440 is positioned within pocket 438 of
segment 430 by longitudinally inserting head 442 into pocket 438 and sliding
component 440 longitudinally within pocket 438. Component 440 and
segment 430 may be placed end-to-end for sliding action. Once head 442 and
component 440 are slid into position within pocket 438, a fastener 39 or
series
of fasteners may be secured to transom 426. Particularly, a fastener 39 is
positioned to inside 435 and placed against inner surface 436. A drill or
screw
driver is activated to drive fastener 39 through segment layer 430 and into
bore
450 of head 442 of component 440. A series of fasteners 39 may be inserted
along the longitudinal aspect of component 440. Fasteners 39 may be inserted
via angled drill/drive devices. Fasteners 39 may be inserted robotically.
After
insertion of fasteners 39, second metal segment 432 is connected to first
metal
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segment 430 to form transom structure 426. In a further aspect, component
440 may also be bonded to metal segment 430. In one instance shoulder 448
may be bonded to outer side face 433' with an adhesive. A heat treatment may
also be applied to assist with the bonding. An adhesive layer may also be
inserted into or used to fasten shoulder 448 to segment 430. Adhesive may
also be used to secure head 442 within pocket 438. Various designs and
configurations of head 438 may be used.
[Para 67] In further respects an aspect of the invention includes the
component 440 itself. Component 440 is a thermally insulating fiberglass
reinforced polymer component 440. Component 440 is for use with a curtain
wall mullion 426 or transom of a curtain wall system. In one aspect component
440 includes a head 442 configured to insert into a pocket 438 defined at an
outer side 433 of a metal mullion or transom 426 of the system. Opposing
shoulders 448 define seal receivers 49 configured to receive a seal oriented
to
abut a panel 50 of the system. Each of the shoulders 448 are configured to
about the outer side 433 of the metal structure 426 such that component 440
covers substantially an entirety of the outer side 433. As shown in Figure 11,
component 440 covers the entirety of the outer side 433 at outer side face
433'. A stem 480 is configured to project into a space between a first panel
50
and a second panel 50 of the system. Stem 480 provides structural support of
the panel 50. Component 440 con'iprises a unitary thermally insulating
fiberglass reinforced polymer. In further aspects component 440 comprises
pultruded fiberglass reinforced polymer. The head 442 defines a head bore
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450 configured to receive a fastener 39 inserted through the metal structure
426 and into the component 480. In further aspects, stem 480 defines a stem
bore 452 configured to receive a fastener 39. The fastener 39 received in stem
bore 452 may be of a different, or the same, variety as the fastener received
at
head bore 450. Stem bore 452 in one aspect is oriented opposite head bore
450.
[Para 68] Figure 12 is a section view of a further aspect of the invention.
Transom 426' is a steel transom having a steel first segment 430' and a metal
second segment 432' which may also be made of steel. Segment 432' may
slide into connected position and friction fit into secure placement. Access
port
434' is used to insert fastener 39 through segment 430' and into component
440. Shoulder 448' is connected to outer side face 433. An adhesive and heat
and pressure techniques may be used to secure or bond shoulder 448' to outer
side face 433'. An adhesive layer may be inserted between shoulder 448' and
face 433'. Fastener 39 is inserted from within segment 430. Several fasteners
39 may be inserted though segment 430 to secure component 440 along the
longitudinal length of segment 430'. It may be appreciated that with the
design of pocket 438' (which lacks ribs 446), head 442 of component 440 may
be inserted by translating component 440 into the pocket 438' and without
requiring a longitudinal sliding action.
[Para 69] Figure 13 is a section view of a further aspect of the invention
Mullion 526 is an aluminum mullion having first segment 530 and a second
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segment 532 connected thereto. Fastener 39 may be positioned at inside 535
of mullion 526 and driven through wall of segment 530 into component 540.
Component 540 includes a head which inserts into pocket 538. Pocket ribs 546
may be used as interlock elements to assist in locking component 540 or
aligning component 540 within pocket 538. An additional component 541 may
also be connected to segment 532 such that together component 540 and
component 541 cover an entirety or substantially the entirety of outer side
533
of mullion. Component 541 may be made of the same or similar material used
to make component 540, and in one aspect is a fiberglass reinforced polymer
and in further aspect is an insulating pultruded fiberglass reinforce polymer.
[Para 70] Figure 14 is a section view of a further aspect of the invention.
Mullion 526' is a steel mullion having a first segment 530' and a second
segment 532' connected thereto. Second segment 532' may also be made of
steel. Component 540' is secured to segment 530' with a fastener 39. An
optional washer may be placed between fastener 39 and the inner surface 536
of segment 530'. An optional washer may also be used with the other aspects
described herein. A second component 541' may be connected to segment
532'. Component 541' may be bonded to segment 532'. Second component
541' may also be connected to segment 532' with a fastener which runs from
inside 535' of mullion 526 through a wall of transom segment, either 530 or
532, and into component 541.
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[Para 71] Figure 15 is a section view of a further aspect of the invention.
Mullion 626 includes a metal segment 630 and a second metal segment 632
which slide together for an adjustable connection. For instance, segments 630,
632 may slide relative to each other in the direction of arrow A to form a
mullion 626. A fastener 39 inserts from inside 635 of segment 630 through a
wall of segment 630 and into component 640. Component 640 may be made
of a polymer material as noted herein. Component 640 is connected to
segment 630 by fastener 39. Interlock rib 646 may be used to form an
interlock to secure component 640 within a pocket 638. Component 640 is slid
longitudinally into pocket 638 to be secured to segment 630 and/or secured
via fastener 39 and/or both. An adhesive may also be used to secure
component 640 to segment 630. An adhesive bonding may be used together
with a fastener and also together with an interlock as desired. As shown in
Figure 15, a rib or ribs and pocket similar to rib 646 and pocket 638 may also
be provided by segment 632 to secure component 641. An interlock and/or
fastener 39 and/or both and or adhesive and/or all of such connections may be
used to connect component 641 to segment 632. An adhesive may also be
used, including an adhesive layer together with heat and pressure treatments
used to bond or secure component 640, 641 to mullion 626.
[Para 72] Component 640, 641 includes stem 680 which extends between
panels 50. A leg 690 wraps laterally and over (and covers) a portion of panel
50 as shown. A portion of panel 50 is also covered by shoulder 648. Shoulder
648 and leg 690 each define a seal receiver 49. Component 640 may be
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secured to segment 630 using several fasteners 39. Thereafter panel 50 may
be secured using component 640 and with seal placed in seal receivers 49 and
adhered to panel 50. Likewise, component 641 may be fastened to segment
632 with several fasteners 39 and then panel 50 connected to component 641
by use of seals and adhesive. Segment 630 and segment 632 may then be slid
or adjustably connected together. The segments 630, 632 may also be
conveniently disconnected by relative sliding along direction of arrow A. When
segments 630, 632 have been connected together, mullion 626 may be
connected to the building structure. It may be appreciated that an entirety or
substantially the entirety of outer side 633 of combined segment 630, 632 (or
of individual segments 630, 632) is covered by components 640, 641 with
portions of components 640, 641 contacting segments 630, 632. Further, it
may be appreciated that no pressure plate or exterior fastener is required to
secure panel 50 to segments 630, 632. In one aspect, components 640, 641
comprise pultruded fiberglass polymer and are configured to wrap about the
edge of panel 50. Components 630, 632 define bore 450 to receive fasteners
39.
[Para 731 Figure 16 is a section view of a further aspect of the invention.
Transom 726 includes metal segment 730 and metal segment 732 connected
thereto. A wing 727 projects from segment 730 to a gap between panels 50,
50. Fastener 39 is secured through wing and into component 740. Component
740 may include a bore to receive fastener 39. In one aspect wing 727 projects
perpendicularly or generally perpendicularly from outer side face 733'. In one
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aspect, fastener 39 is oriented perpendicular or generally perpendicular to
wing
727. Component 740 may be a polymer component as described herein. A
second component 741 is connected to segment 732. Component 741 may be
connected via adhesive or bonding. A fastener may also be secured from and
through inside of segment 732 and into component 741. In further aspects
component 741 may include a bore to receive a fastener. Component 740
wraps around to both sides of panel 50 as shown. An entirety of outer side 733
of combined segment 730, 732 is covered by components 740, 741, 742. Such
components 740, 741, 742 also contact outer side 733 of segments 730, 732.
Component 741 may include an interlock which inserts into a corresponding
interlock of segment 732. Component 741 may also include a seal receiver
which receives a seal to abut against panel 50. An additional component 742
may be used to cover wing 727 as shown and to provide further insulating
protection of segments 730, 732. Component 742 may be connected to wing
727 by adhesive and/or a fastener. A further component 743 includes a seal
receiver and receives a seal to abut against panel 50. Component 743 may
comprise a metal or in other aspects may also comprise a fiberglass
component. An end of component 743 opposite seal receiver includes a rib or
ribs which insert into corresponding rib or ribs of component 740 for secure
positioning of component 743. In addition to use of fastener 39, or as an
alternative to fastener 39, an adhesive may be used to rigidly bond component
740 to outer side face 733'. Such bonding may be made by use of an adhesive
and other forms of bonding may also be used. Additionally, or alternatively, a
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rib 746 may also be used to secure or assist in rigidly securing component 740
to face 733'. A spacer may be inserted into cavity 792 of transom 726 so that
panel 50 may rest against the spacer so that the weight of panel 50 may be
supported by component 740. Component 740 may also include a weep hole
or weep holes to allow moisture to escape from cavity 792.
[Para 74] Figure 17 is a section view of a further aspect of the invention.
Transom 826 includes metal segment 830 which may be aluminum for
instance. Segment 830 mates with segment 832 which may also be made of
metal such as aluminum. Component 840 is connected to outer side 833 of
transom 826. In one aspect component 840 connects to wing 827 and is
configured to cover the entire outer side of segment 830. Component 840 may
include a bore configured to receive fastener 39 inserted through wing 827. An
adhesive may also be used to secure component 40 to segment 830. A strip or
sheet of double back adhesive may be used. Heating, pressure and additional
bonding techniques may be used to connect a component to the metal herein.
Various interlocks, ribs and grooves may also be used to secure component
840 to segment 830. Segment 830 may include a rib 846 or ribs which mate
with component 840 for interlocking arrangement. Component 840 may
include leg 890 which extends to an outer side of panel 50 and transom 826
and may include a seal receiver to receive a seal to abut against panel 50.
Component 840 may also include a weep hole 891 or a series of weep holes to
allow moisture to escape from cavity 892. Component 840 includes a further
seal receiver to receive a seal to abut panel 50 on an inner side of panel 50.
It
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may be appreciated that component 840 wraps around to both sides of panel
50. A spacer may also be positioned in cavity 892 so that panel 50 may rest
upon the spacer which in turn rests upon component 840. Component 840
supports the weight of panel 50.
[Para 75] A component 841 is connected to segment 832 at jaw 829. The
entirety of the outer side of jaw 829 is covered by component 841. Component
841 wraps around a tip of jaw 829. Component 841 includes a seal receiver for
receiving a seal to abut against an inside of segment 830. An optional air
baffle 843 is placed within segment 839. In one aspect baffle 843 may be
about 4 inches in length and is positioned where the vertical mullion
terminates
or at the top of the vertical mullion to prevent air leaks. In one aspect
baffle
843 fits snugly into a channel defined in part by various walls of segment 830
as shown. A tip of jaw 829 inserts into the channel and the component 841
abuts baffle 843 which also seals outer face of segment 830 from exposure.
Segment 842 is also connected to segment 830 and covers wing 827 and
isolates wing 827 and walls of segment 830 from the atmosphere or exposure.
It may be appreciated that components 841, 842 may be secured to segments
830, 832 by adhesive, including a double backed strip adhesive and under
pressure and temperature for bonding. In alternative aspects components 841,
842 may also be fastened with a fastener. Components 841, 842 may also
define respective bores for receiving fasteners. Components 840, 841, 842
may be secured by use of adhesive and/or fasteners and/or interlock/friction
fit
or all of the same. An end cap 893 connects securely to component 840 via
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friction fit or snap-n fingers and includes a seal receiver and seal to abut
panel
50 which is held in place at panel 832. An adhesive block or connector 895 is
used to secure panel 50 to segment 832. It may be appreciated that segment
830 and 832 come together to form transom 826 and the individual segments
830, 832 are connected to respective structure elements of the building to
secure transom 826 and panels 50 into position. While the unitized design
shown in Figure 17 depicts a transom made of metal such as aluminum, it may
be appreciated that such transom structure may also be made with steel, of
course with some structural modifications to accommodate for the bending of
the steel segments comprising the transom.
[Para 761 It should be understood, of course, that the foregoing relates to
exemplary embodiments of the invention and that modifications may be made
without departing from the spirit and scope of the invention as set forth in
the
following claims. The scope of this invention also includes embodiments
having different combinations of features and embodiments that do not include
all of the above described features.
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