Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02951502 2016-12-07
TITLE OF INVENTION
CURTAIN WALL MULLIONS, TRANSOMS AND SYSTEMS
DESCRIPTION
BACKGROUND
[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
components such as mullions or transoms that include a thermally insulating
component. In some embodiments, the insulating component is a fiberglass
component such as a fiberglass reinforced polymer that is bonded to a metal
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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 31 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
component bonded to the metal structure, a panel secured to the cell, the
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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] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[Para 8] 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 9] Figure 1 is a front view of a cell of a curtain wall system
according
to some embodiments of the present invention.
[Para 10] Figure 2 is a sectional view of a mullion along line 2-2 of
Figure
1, according to some embodiments.
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[Para 1 1 ] Figure 3A is a sectional view of a transom along line 3-3 of
Figure 1, according to some embodiments.
[Para 1 2] Figure 38 is a sectional view of a transom along line 3-3 of an
alternative aspect of Figure 1, according to some embodiments.
[Para 13] 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 14] 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 5] 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.
[Para 16] 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 1 7] Figure 6 is a sectional view of a mullion along line 2-2 of
Figure
1, according to some further embodiments.
[Para 1 8] Figure 7 is a sectional view of a transom along line 3-3 of
Figure
1, according to some further embodiments.
[Para 19] Figure 8 is a sectional view of a mullion along line 2-2 of
Figure
1, according to some further embodiments.
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[Para 20] Figure 9 is a sectional view of a mullion along line 2-2 of
Figure
1, according to some further embodiments.
[Para 21] Figure 10 is a sectional view of a mullion positioned along an
end
wall of Figure 1, according to some further embodiments.
[Para 22] 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 23] 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
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,
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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 24] 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
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.
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[Para 25] 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
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
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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 261 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
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.
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[Para 27] 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 therebetween. Shoulder
70 may friction fit or interlock and/or bond to tail 35.
[Para 28] 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
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panels 50, 50'. Maintaining the segments of mullion 24 in isolation from the
outside atmosphere improves the insulating characteristics of system 22.
[Para 29] 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 30] 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
130. Wall 130 is formed of metal and in one aspect is formed of steel and in
one aspect is bent into configuration.
[Para 31] 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.
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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, SO' and other forces associated with or
applied
to the panels.
[Para 32] 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
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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 33] 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 34] 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
panel frame 52. Seal 60 may be of a conventional variety used in curtain wall
systems.
[Para 35] 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 SO. It may
be appreciated that component 140 together with pressure plate 36 secure
panels 50, 50' to transom 26.
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[Para 36] 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 37] 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
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 SO, 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
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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 moled 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 SO, 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
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 38] 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
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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 SO'
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 39] Figure 3D shows a further aspect of transom 26 having a
symmetrically disposed polymer component 40 and where the transom 26 is
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 40] 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
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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.
[Para 41] 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.
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[Para 42] 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
variety used in curtain wall systems. Polymer component 340 in this aspect
completely covers outer side 325 of transom 326.
[Para 43] 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
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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 44] 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 45] Figure 8 shows a polymer component 40 bonded to mullion 24.
In this aspect mullion includes first mullion segment 30 having a tail 31a
leading to arm 31 b 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 sedond 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
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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 46] 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, SO' 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 47] 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
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 SO' may also be fastened to
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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 48] 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.
[Para 49] 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 50] 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
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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 51] 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
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 52] 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
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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
desired tolerances and long lengths) without having to purchase or design new
equipment or tooling.
[Para 53] 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
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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 54] 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
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
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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 55] 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
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 56] 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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