U.S. patent application number 11/192842 was filed with the patent office on 2007-02-01 for panel wall system.
This patent application is currently assigned to Engineered Extension Systems LLC. Invention is credited to Jeb Morgenegg, Randall Robertson.
Application Number | 20070022682 11/192842 |
Document ID | / |
Family ID | 37692768 |
Filed Date | 2007-02-01 |
United States Patent
Application |
20070022682 |
Kind Code |
A1 |
Morgenegg; Jeb ; et
al. |
February 1, 2007 |
Panel wall system
Abstract
Several curtain wall system embodiments are described including
dry system embodiments, wet system embodiments and a rain screen
system embodiment. The dry system embodiments utilize a subframe
grid that is comprised of tubular subframe members. The subframe
members are interconnected to form a typically rectangular grid
that is attached to the substructure of a building using subframe
attachment clips that are longitudinally slidably coupled with the
subframe members. Panel assemblies are coupled to the subframe grid
in a manner that facilitates a water tight seal. In one embodiment,
the panel assemblies include perimeter frame members that can be
used interchangeably with dry, wet and rain barrier curtain wall
systems.
Inventors: |
Morgenegg; Jeb; (Aurora,
CO) ; Robertson; Randall; (Lakewood, CO) |
Correspondence
Address: |
LEYENDECKER LEMIRE & DALEY, LLC
C/O PORTFOLIO IP
P.O. BOX 52050
MINNEAPOLIS
MN
55402
US
|
Assignee: |
Engineered Extension Systems
LLC
|
Family ID: |
37692768 |
Appl. No.: |
11/192842 |
Filed: |
July 29, 2005 |
Current U.S.
Class: |
52/235 |
Current CPC
Class: |
E04B 2/90 20130101; E04F
13/0889 20130101 |
Class at
Publication: |
052/235 |
International
Class: |
E04H 3/00 20060101
E04H003/00; E04H 5/00 20060101 E04H005/00 |
Claims
1. A curtain wall system comprising: a subframe grid including a
plurality of interconnected elongated subframe members, the
plurality of elongated subframe members being tubular, each
elongated subframe member having a first side, the first side
having generally flat outwardly-facing mating surface; a plurality
of gaskets comprised of an at least partially elastomeric sheet
material, the gaskets adapted to cover at least a significant
portion of the mating surfaces of the subframe members; and a
plurality of panel assemblies, each panel assembly including a
panel having exterior and interior face surfaces, each panel
assembly being adapted to couple with the subframe grid.
2. The curtain wall system of claim 1, wherein the panel assembly
further comprises a frame comprising a plurality of coupled frame
members, the plurality of frame members being coupled to the
interior face surface of the panel proximate the periphery of the
panel assembly.
3. The curtain wall system of claim 1, further comprising: a
plurality of subframe attachment clips, each subframe attachment
clip having a first portion; and wherein each subframe member of
the plurality of subframe members further includes a second side
opposite and spaced from the first side, the second side including
one or more slots formed therein, the one or more slots extending
longitudinally along the frame member, each slot adapted to receive
the first portions of one or more subframe attachment clips therein
and permit slidable longitudinal movement of the one or more
subframe attachment clips along the subframe member while hindering
the removal of the first portion from the slot laterally.
4. The curtain wall system of claim 3, wherein each subframe
attachment clip further includes a second portion, the second
portion being integrally formed with the first portion and being
adapted to receive one or more fasteners therethrough for securing
the subframe attachment to the substructure of an associated
building.
5. The curtain wall system of claim 3, wherein the first portion
has a T-shaped cross section.
6. The curtain wall system of claim 3, wherein each of the one or
more slots has a T-shaped cross section.
7. The curtain wall system of claim 1, wherein the plurality of
subframe members are extruded of an aluminum alloy.
8. The curtain wall system of claim 2, wherein each frame member
includes a bottom side having an outside surface with one or more
generally pointed ridges extending longitudinally along the outside
surface, the one or more pointed ridges being adapted to press into
a top surface of a corresponding gasket of the plurality of gaskets
to inhibit water penetration there across.
9. The curtain wall system of claim 1, further comprising a
plurality of union sleeves, each union sleeve being sized to at
least partially fit snuggly within a tubular interior of each
subframe member of the plurality of subframe members, the union
sleeve being adapted to facilitate the coupling of two subframe
members together.
10. The curtain wall system of claim 9, wherein an outside surface
of each union sleeve of the plurality of union sleeves is
ribbed.
11. The curtain wall system of claim 1, further comprising (i) a
plurality of elongated lock bars and (ii) a plurality of threaded
fasteners, each lock bar adapted to clamp the interior face
surfaces of two adjacent flat panels to a top surface of a gasket
of the plurality of gaskets when the lock bar is coupled to a
corresponding subframe member of the plurality of subframe members
with one or more threaded fasteners of the plurality of threaded
fasteners to inhibit water penetration across an interface of the
interior face surface and the top surface.
12. The curtain wall system of claim 11, further comprising a
plurality of gasket strips, the gasket strips being comprised of an
at least partially elastomeric sheet material, each gasket strip
being adapted to be placed between an exterior face surface of a
flat panel proximate an edge of the panel and sandwiched between
the exterior face surface and an underside surface of a
corresponding lock bar when the corresponding lock bar is coupled
to the corresponding subframe member to inhibit water penetration
across interfaces of (i) the exterior face surface and a bottom
surface of the gasket strip, and (ii) the underside surface and a
top surface of the gasket strip.
13. A subframe grid of a curtain wall system, the subframe grid
being adapted for coupling to (i) the structure of a building and
(ii) a plurality of curtain wall panel assemblies, the subframe
grid comprising: a plurality of elongated subframe members, the
subframe members being interconnected to form a grid, each of the
subframe members being tubular and having (i) a flat outwardly
facing surface and (ii) one of one or more longitudinally-extending
slots formed therein; and a plurality of subframe attachment clips,
each subframe clip having a first portion and a second portion, the
first portion adapted to be received in a slot of the one or more
slots of the subframe members permitting slidable movement along
the slot while hindering removal from the slot laterally, the
second portion adapted to receive a fastener therethough to couple
the subframe attachment clip to a substructure of a building.
14. The subframe grid of claim 13, further comprising a plurality
of union sleeves, each union sleeve being sized to at least
partially fit snuggly within a tubular interiors of the plurality
of subframe members, the union sleeve being adapted to facilitate
the coupling of two subframe members together.
15. The subframe grid of claim 13, wherein (i) each subframe member
includes a building-facing surface substantially opposite the
outwardly facing surface, the building-facing surface having
longitudinally-extending left and right edges, and (ii) the one or
more longitudinally-extending slots comprises a first slot and a
second slot, the first slot extending inwardly from the
building-facing surface generally proximate the left edge and the
second slot extending inwardly from the building-facing surface
generally proximate the right edge.
16. The subframe grid of claim 13, wherein the first portion and
the slots have corresponding T-shaped cross sections.
17. The subframe grid of claim 13, further including a plurality of
self tapping threaded fasteners, the threaded fasteners adapted to
be received through the second portion of the subframe attachment
clips and into the substructure of the building.
18. A subframe member for use in a subframe grid of a curtain wall
system wherein the subframe grid is attached to a substructure of a
building using a plurality of clips adapted be slidably received on
the subframe member, the subframe member being (i) longitudinally
elongated and (ii) tubular in cross section, and having (a)
opposing first and second sides and (b) at least one of the group
consisting of a longitudinally-extending slot and a
longitudinally-extending appendage, the first side being generally
flat, the at least one slot or at least one appendage being adapted
to receive at least one of the plurality of clips thereon to permit
slidable movement along the slot or clip while hindering lateral
removal of the clip from the slot or appendage.
19. The subframe member of claim 18, wherein the at least one of
the group consisting of the longitudinally-extending slot and the
longitudinally-extending appendage comprises the longitudinally
extending slot, the slot being located on the second side.
20. The subframe member of claim 18, wherein the subframe member is
extruded and is comprised of an aluminum alloy.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to exterior walls of
industrial and commercial buildings and, in particular, a curtain
wall system comprising a plurality of individual panels that are
removably coupled to the exterior of a building.
BACKGROUND
[0002] A typical curtain wall panel system comprises a plurality of
rectangularly-shaped metal panels, (ii) a rigid panel perimeter
frame, hereafter generally referred to as perimeter extrusion (PE),
that extends around the perimeter of each panel, and (ii) a means
for attaching the panels to the exterior walls of a building. The
panels in many instances are made from metal composite material
(MCM) sheet stock that is manufactured separately. MCM sheet stock
consists of two thin outer sheets of metal that are bonded to an
internal synthetic core to create a sandwich composite sheet. The
outermost metal sheet may be finished to provide the exterior of
the associated building with an attractive appearance. These MCM
sheets are processed further by the panel system manufacturer via
routers and/or saws to yield individual attachable panels.
[0003] The rigid PE frame usually comprises a plurality of linearly
extruded metal (most often aluminum) pieces that have a shape and
configuration specifically adapted to be coupled to both the
attachment means and the perimeter of the MCM panel. The extruded
PE frame pieces are typically joined together where they intersect,
at the respective corners of an associated MCM panel, to
substantially encompass the entire perimeter of the MCM panel.
Typically, the coupling between the MCM panel and the respective
extruded PE frame pieces provides a water tight seal therebetween.
The manner in which the extruded PE frame pieces couple with the
attachment means and whether the coupling is water tight depends on
the particular attachment means and the specific type of curtain
wall system for which the extruded PE frame pieces and the
associated attachment means are configured.
[0004] There are at least three types of curtain wall panel systems
and two main installation sequence types. The panel system types
are: (i) rain screen systems; (ii) wet seal systems; and (iii) dry
seal systems. The installation sequence types are: (i) sequential
install and (ii) non-sequential install. Each system and
installation sequence type has advantages and disadvantages
compared to the others. Further, the components of a particular
curtain wall system are typically configured for one type of system
and cannot be used in another type system. For instance, the
extruded PE frame pieces of a dry seal system typically cannot be
used on a wet seal system. Accordingly, once a panel has been
assembled with the extruded PE frame pieces, the resulting assembly
is generally only suitable for use with a particular dry, wet or
rain screen system.
[0005] A dry seal system, hereafter referred to as a dry system, is
one in which gaskets and solid seals are utilized to prevent or
substantially inhibit the penetration of water across the joint
between the PE frame pieces and the attachment means, and
accordingly behind the panels and potentially into the building. In
a wet seal system, hereafter referred to as a wet system, uncured
caulking, opposed to a gasket, is applied in the joints between the
attached panel assemblies to prevent or substantially inhibit the
penetration of water. In a rain screen system, also referred to
herein as an accent strip system, the joints are not sealed against
water penetration. Accordingly, when using a rain screen type
system the building is typically sheathed in plywood, exterior
grade gypsum board or other equivalent materials and further
covered with Tyvex.TM. or another type of barrier to prevent
moisture from entering the building. It is further appreciated that
when wet systems are used, the associated building is also usually
sheathed and covered with a moisture barrier as is usually
specified by the building's engineer or designer. Typically, dry
seal systems are the most expensive to fabricate and install, but
offer the best finish as the panel fasteners and the space between
adjacent panels are usually covered with a finished metal cover
cap. Dry systems typically maintain longer warranty periods and
have much greater performance characteristics that those of wet and
rain screen systems. These superior characteristics allow the
option of a dry system to be installed directly over buildings
structural members without any sheathing or moisture barriers,
again a factor that must be considered when choosing a system.
[0006] Most wet seal and rain screen systems are sequentially
installed, linking one panel to another in some manner. There are a
few dry systems that are non-sequential, but they are costly and
have complex parts system. Sequential systems are simple to install
on basic buildings, but become very difficult to install as the
building geometry becomes more complex. The linkage between each
panel in a sequential system makes the task of replacing panels
time consuming and difficult. In this situation most panels must be
cut off the building, possibly damaging other panels in the
process. Due to the interruption of the sequential linkage between
panels, substantial modifications must be made in order to insert
the new panel when it is ready to be placed back on the building.
Because the panels are not inter-linked one to another as in a
sequential system, non-sequential systems allow more flexibility
with more complex building geometries, as well as when damaged
panels need to be removed.
[0007] Typically, a wet system is less expensive than a dry system
since a lower number of components are utilized; however, it does
not typically have as pleasing an appearance as a dry system.
Replacing a damaged panel assembly on a wet system wall is more
costly and time consuming as the caulking has to be first removed
to access the fastener, which secures the panel assembly to the
building, and new caulk must be applied once the replacement panel
assembly has been put back in place. It is further appreciated that
many wet systems are not designed or configured to facilitate easy
replacement of a damaged panel assembly the caulk notwithstanding,
making removal and replacement of panel assemblies a very
substantial undertaking. This is not necessarily an absolute
negative but a consequence that must be weighed against the lower
cost of using the wet system in the first place. In addition, over
time the joint caulking used in wet systems fade, discolor, attract
and hold dust and dirt. Further, they also have a tendency to
`bleed` onto the finished face of adjacent panels, thus causing a
distortion of the panel finish. These issues are of great
importance when weighing which system type one would choose for a
project and the long term costs associated with such systems.
[0008] The rain screen system is typically the least expensive to
purchase and install due to its relative simplicity. However,
because it allows water to penetrate behind the joints between
panel assemblies, it is not a water tight system and the additional
preparation required to the building may negate some of this
system's cost advantage. In general rain screen systems have no
true seal at the panel joints but rely on the fact that most of the
water that the building will face will be blocked by the panels.
The water that is not blocked by the panels penetrates the joints
and, it is hoped, that the sheathing and membrane placed behind the
panels on the building will withstand the moisture. Because the
rain screen panel joint is typically recessed relative to the
outside surfaces of the panel assemblies, it may not be as
aesthetically pleasing in appearance as the dry system, yet it is
often preferable in appearance to the wet system. Its installation
is similar to that of the wet system and offers further
installation cost savings by eliminating the need to caulk the
joints; however, repair and replacement of panel assemblies can be
time consuming and costly as this type of system is often not
designed and configured to facilitate easy and quick panel assembly
replacement. Because water can penetrate behind this type of
curtain wall panel system, the associated building is usually
sheathed in plywood, exterior grade gypsum board or other
equivalent materials and further covered with Tyvex.TM. or another
type of barrier to prevent moisture from entering the building.
This may reduce the cost savings advantage of the rain screen
system somewhat relative to the other types of systems.
[0009] It is appreciated that a particular building may utilize
more than one type of panel system in its construction to provide
the best balance between building economy and appearance. For
instance, to save money, an architect may specify a dry system on
the most exposed sections of a building while using the less
expensive rain screen system on exterior walls of the building
located in alcoves and overhangs where water is less likely to
penetrate the structure. Likewise, the more attractive dry system
may be used on the front side of a building and a wet system on the
sides and back of the building.
[0010] As discussed above, the dry system typically is the most
expensive system to purchase and install primarily because of the
additional components utilized in the attachment means of the dry
system and the time required to fabricate and install those
additional components. Specifically, dry systems often utilize
subframes grids that are attached to a building's studs on top of
which the panel assemblies are attached. The subframes provide an
interface to which corresponding surfaces of the PE frame pieces
can be coupled and provide a substantially water impervious
joint.
[0011] Typically, the subframe grid sections are fabricated offsite
based on an architect's specifications and verified field
dimensions. The sections are shipped to the building site, attached
to the building and joined together. The various grid pieces are
joined together by bolting intersections between the various
sections. As can be appreciated, wherever the grid is joined
together, there is a potential for water seepage behind the panel
assembly joints.
[0012] According to the architect's plan, various panel assemblies
are fabricated and then later shipped to the building site to be
secured to the subframe grid. The extruded PE frame pieces, which
are integral within the panel assemblies, must match up with the
corresponding mating surfaces of the subframe members. The
acceptable tolerances at these joints are typically about 0.125''
wherein any greater variations will require the offending panel or
subframe to be remanufactured. Ultimately, the panel assemblies and
the subframe grid sections in typical dry system must be fabricated
to extremely high tolerances.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a front elevation view of a typical subframe grid
attached to a building according to one embodiment of a dry
system.
[0014] FIG. 2 is an exploded view of a typical panel assembly in
various stages of assembly according to one embodiment of a curtain
wall system.
[0015] FIG. 3 is a cross sectional partially exploded side view of
a typical midwall joint according to one embodiment of a dry
system.
[0016] FIG. 4 is a cross sectional partially exploded side view of
a typical inside corner joint according to one embodiment of a dry
system
[0017] FIG. 5 is a cross sectional partially exploded side view of
a typical termination joint according to one embodiment of a dry
system.
[0018] FIG. 6 is a cross sectional side view of a subframe member
according to one embodiment of a dry system.
[0019] FIG. 7 is a cross sectional side view of a subframe
attachment slide clip according to one embodiment of a dry seal
system.
[0020] FIG. 8 is a cross sectional side view of a PE attachment
slide clip according to one embodiment of a wet system
[0021] FIG. 9 is a cross sectional side view of a PE member
according to one embodiment of dry, wet and rain screen
systems.
[0022] FIG. 10 is a cross sectional side view of a lock bar member
according to one embodiment of a dry system.
[0023] FIG. 11 is a cross sectional side view of a joint snap cover
member according to one embodiment of a dry system.
[0024] FIG. 12 is a cross sectional side view of a subframe union
sleeve member according to one embodiment of a dry system.
[0025] FIG. 13 is a top view of a twist-lock joint anchor according
to one embodiment of a wet system.
[0026] FIG. 14 is a cross sectional side view of a wide lock bar
member according to one embodiment of a dry system.
[0027] FIG. 15 is a cross sectional side view of a joint snap cover
member for use with the wide lock bar member of FIG. 14 according
to one embodiment of a dry system.
[0028] FIG. 16 is a cross sectional side view of a typical outside
corner condition according to one embodiment of a dry system.
[0029] FIG. 17 is a cross sectional partially exploded side view of
a typical midwall joint according to one embodiment of a wet
system.
[0030] FIG. 18 is a cross sectional partially exploded side view of
a typical head termination joint detail according to one embodiment
of a wet system.
[0031] FIG. 19 is a cross sectional partially exploded side view of
a typical sill termination joint detail according to one embodiment
of a wet system.
[0032] FIG. 20 is a cross sectional side view of a typical midwall
joint detail according to one embodiment of a rain screen
system.
[0033] FIG. 21 is a cross sectional side view of a typical subframe
union joint detail according to one embodiment of a dry system.
[0034] FIG. 22 is a partially exploded front elevation view of a
typical subframe union joint detail according to one embodiment of
a dry system.
[0035] FIG. 23 is a cross sectional side view of a typical midwall
joint detail according to a second embodiment of a wet system.
[0036] FIG. 24 is a cross sectional side view of a typical midwall
joint detail according to a second embodiment of a dry system.
DETAILED DESCRIPTION
[0037] One embodiment of a curtain wall system is described
incorporating improved subframe members that allow for more
simplified installation, extruded panel perimeter frame members
(also referred to as PE members) that offer more flexibility during
panel assembly and installation, fastening elements and gaskets
that provide superior resistance to water penetration at the panel
joints than prior art systems, but additionally permit greater
tolerance error during assembly and installation than prior art dry
systems.
[0038] The subframe members of the one embodiment are tubular;
providing a channeled path that acts a gutter to transport away any
water that does manage to penetrate past the gasket and fastener
used to secure the panel assemblies to the subframe grid.
Attachment clip slots are provided lengthwise on the underside of
the tubular subframe members to accept and permit subframe
attachment clips to freely slide therein along the length of the
subframe member. The sliding subframe attachment clips and the
associated slots eliminate the need for a continuous flange that
extends the entire length of the subframe member, as the subframe
attachment clips are simply slid to the locations of studs or other
attachment points on the associated building. The sliding subframe
attachment clips include an outwardly protruding leg portion that
extends to the side of the subframe members through which leg a
self tapping fastener is threaded to secure the clip and subframe
to a stud (or other structural element) of the building. Due to the
replacement of a continuous flange by the sliding clip method, the
weight of the subframe members is reduced when compared to prior
art systems.
[0039] The gasket material, which typically comprises an elastomer
such as Santoprene, typically covers substantially the entire width
of the mating surface of the subframe members, thereby providing a
larger surface seal and thus greater resistance to water
penetration than narrower gaskets used in the prior art systems.
Additionally, the bottom mating surfaces of the PE members that are
attached to the perimeters of the MCM panels include small pointed
downwardly facing ridges that bite into the gasket material when
the PE members are secured against the gasket material by way of
lock bar members and threaded fasteners, thereby forming a more
positive seal than prior art systems.
[0040] The one embodiment also comprises improved PE members. The
improved PE members include (i) the aforementioned pointed
downwardly facing ridges; (ii) ribbing along the PE member surfaces
that mate to the perimeter sides of an associated MCM panel,
thereby providing channels for caulking that is used to seal the
panel to the frame member; (iii) channels for accepting sliding
attachment clips permitting the PE members to be used in wet and
rain screen systems in addition to dry systems; and (iv) an MCM
panel stop rib that provides an edge against which to butt the end
of an MCM panel and ensure uniform alignment of all panel
assemblies of a particular curtain wall.
[0041] In the one embodiment, an improved lock bar for use in
combination with self tapping threaded fasteners to secure the
respective panel assemblies to the gasketed subframe is also
provided. The lock bar typically comprises an extruded bar having a
specific cross sectional shape that fits in-between the downwardly
folded edges (also referred to as "panel returns"), of an assembled
MCM panel and bears against the outwardly extending bottom leg of
an associated PE member. The lock bar accepts fasteners through its
top surface and as the fastener is secured into the subframe member
the bearing surface of the lock bar presses the bottom sides of the
PE leg into the gasket material which is backed by the subframe
member's top surface. The improved lock bar features include: (i) a
shallow centrally located v-shaped channel that extends
longitudinally along the top surface of the lock bar to facilitate
accurate drilling of fastener holes through the lock bar; (ii) a
second centrally located longitudinally-extending channel located
in the bottom horizontal surface of the bar's hollow interior to
further assist in drilling aligned fastener holes; (iii) a
longitudinally-extending compression ridge having a flat bottom
surface that extends below the bearing surfaces that are incident
against the outwardly extending bottom leg of the PE, such that the
flat bottom surface further compresses the gasket material
downwardly and around the fastener that passes through the bottom
surface and the gasket into the subframe member; and (iv) generally
vertical edges on the compression ridge that act as stops for the
extruded frame member bottom side edges assuring that the two panel
assemblies are evenly and accurately spaced. It is appreciated in
other dry systems without stops or a compression ridge that the
bottom sides may or may not be butted up against the fastener and
the result is potentially uneven spacing between the panel edge of
one panel assembly and the cover cap (which is snapped on to the
lock bar) when compared to the panel edge of the adjacent assembly
and the opposite side of the cover cap.
[0042] In an another embodiment of a dry system, tubular subframe
members including slots into which sliding clips can be received
are also utilized; however, the rigid panel frames of the panel
assembly that typically comprise the PE members are completely
eliminated. Rather, portions of the MCM panels proximate their
edges are clamped against the subframe member and a gasket
overlying the subframe member to form a water tight seal. The
clamping force is provided by wide lock bar member that is fastened
to the subframe member by way of a self threading fastener. An
elongated cover cap is provided to cover the channel formed in the
wide lock bar and hide the fasteners from view.
[0043] This other embodiment of a dry system provides several
advantages over other dry systems. Namely, because the PE members
are eliminated, the resulting curtain wall has a lower profile than
other dry systems. Lower profile systems are often preferred by
architects. Additionally, because PE members are eliminated, the
panels can as necessary be cut at the job site. Accordingly, the
need to have new panel assemblies fabricated offsite if there is a
dimensional discrepancy between a panel assembly and the subframe
assembly is eliminated saving downtime and fabrication cost.
[0044] Several embodiments of wet systems are also described
herein. In one embodiment of a wet system, the PE members forming
the frames of the applicable panel assemblies are connected to the
building by way of clips that are slidably received in slots
provided in the PE members. As mentioned above, the PE members
utilized in this wet system embodiment can be the same PE members
used in one embodiment of the dry system. Advantageously, a
provider of dry and wet systems need only stock a single type of PE
member thereby reducing warehousing and other costs. In variations
of this embodiment, PE members that are different from the PE
members used in dry systems can also be used.
[0045] In another type of wet system embodiment, the sliding clips
are not utilized but a plurality of twist lock plates that are
arranged around the sides of a panel assembly are used to secure
and lock the panel assembly in place. As will become more apparent
from the description provided herein below, the use of twist lock
plates permits a non-sequential installation of the associated wet
system and also facilitates the easier replacement of damaged panel
assemblies on a building having a wet system curtain wall.
[0046] The advantages provided, the various embodiments described
above and herein are not intended to be construed as limiting.
Rather, numerous variations and numerous embodiments have been
contemplated that read upon the appended claims and are intended to
be within the scope of the invention.
Terminology
[0047] The term "or" as used in this specification and the appended
claims is not meant to be exclusive rather the term is inclusive
meaning "either or both".
[0048] References in the specification to "one embodiment", "an
embodiment", "a preferred embodiment", "an alternative embodiment",
"one variation", "a variation" and similar phrases mean that a
particular feature, structure, or characteristic described in
connection with the embodiment or variation is included in at least
an embodiment or variation of the invention. The phrase "in one
embodiment", "in one variation" or similar phrases as used in
various places in the specification are not necessarily meant to
refer to the same embodiment or the same variation.
[0049] The term "couple" or "coupled" as used in this specification
and the appended claims refers to either an indirect or direct
connection between the identified elements, components or objects.
Often the manner of the coupling will be related specifically to
the manner in which the two coupled elements interact. For example,
the PE members are coupled to the subframe member when the dry
system is installed yet the PE members do not actually contact the
subframe members because of the intervening gasket material.
[0050] Directional and/or relationary terms such as, but not
limited to, left, right, nadir, apex, top, bottom, vertical,
horizontal, back, front and lateral are relative to each other and
are dependent on the specific orientation of an applicable element
or article, and are used accordingly to aid in the description of
the various embodiments and are not necessarily intended to be
construed as limiting.
[0051] As applicable, the term "about" as used herein unless
otherwise indicated means a margin of +-15%. The term
"substantially" as used herein unless otherwise indicated means a
margin of +-10%.
[0052] The phrase "building structure" or "building substructure"
as used herein refer to any structure of a building to which a
curtain wall system and/or its associated components are coupled or
otherwise attached. The building structure or building substructure
can include, but is not limited to, studs and sheathing.
[0053] The term "tubular" as used herein refers to a structure or
member having a hollow elongated and enclosed interior channel with
at least one open end thereof, and is not intended to be limited to
a structure that is cylindrical. For instance, the subframe members
illustrated herein are rectangular in cross section but are also
"tubular".
A First Dry System Embodiment
[0054] FIGS. 1-7, 9-12, 16, 21 & 22 illustrate a dry system and
various components and assemblies thereof.
[0055] FIG. 1 is an illustration of a typical subframe assembly 10
coupled to the studs 15 along the side of a building 20. Typically,
the subframe assembly 10 is assembled at the building site from
subframe assembly sections 25 that are joined together at the
building site. Each section 25 comprises a number of horizontal
subframe members 33 and vertical subframe members 30 that are
joined together to form a plurality of various geometric frame
openings 35. The dimensions of each frame opening generally
correspond with the size of a panel assembly 40 that is attached to
the subframe to cover the corresponding opening 35. Typically, the
subframe assembly sections 25 are fabricated offsite wherein the
subframe members 30 & 33 are welded (or alternatively
mechanically fastened) together. The size of the subframe assembly
sections 25 are limited to a size that can be economically
transported (typically by a trailer truck) to the building
site.
[0056] At the building site, the sections 25 are secured to the
studs 15 of the building 20 by way of sliding subframe attachment
clips 45 that slide along subframe clip slots 47 (see FIG. 3) in
the subframe members 30 and/or 33 so that the sliding clips 45 can
be aligned with the studs 15. Generally, the sliding clips 45 are
inserted into both clip slots 47 of only the horizontal subframe
members 33 due to the fact that the vertical subframe members 30
rarely align with the building studs 15 or other attachment points.
The attachment clips 45 are fastened to the studs 15 preferably
using self tapping fasteners 50 that each simultaneously drills and
threads itself through an associated sliding clip 45 and stud 15.
It is appreciated that metal studs are not the only material to
which the panel system can be attached. CMU, structural steel, wood
framing as well as other materials can readily serve as attachment
surfaces. While the frame clips are typically and preferably
attached to the building's studs 15, it is to be appreciated that
the subframe members can also be attached to rigid sheeting, such
as plywood, orientated strand board or other similar materials. As
illustrated herein, the studs 15 and/or other attachment locations
of the subframe members 30 or other components, such as used in the
wet and rain screen system, are collectively illustrated as the
building wall/substructure 475 in the various figures.
[0057] As the subframe assembly sections 25 are secured to the
building 20, adjacent sections are joined together to form a union
joint 17 as illustrated in FIGS. 21 & 22. To join two pieces of
subframe members 30 and/or 33, a union sleeve 55 (see FIG. 12)
coated with waterproof caulking adhesive (not shown) is fitted
about halfway into one of the subframe members 30 and/or 33 being
joined. The union sleeve 55 can be made of any suitable material
but is preferably made of aluminum. In preferred variations of the
union sleeve, the mating surface of the sleeve is ribbed as shown
in FIG. 12 to better hold the caulk and facilitate a more water
tight seal. The interior of the subframe member can also be coated
with caulking compound. The union sleeve 55 is inserted equally
into the interior of each adjacent subframe piece and secured in
place with self tapping screws 50 placed along the sidewalls of the
subframe member so as to penetrate the subframe sidewall and into
the tubular union sleeve. By securing the frames together through
the sidewalls, the subframe attachment clip slots remain
un-obstructed, thus allowing clips to slide past the union
intersection as needed. This method also allows the gasket 155 (see
FIG. 3) to span across the union of the subframe members
uninterrupted, thus guarding against the influx of moisture at the
union point.
[0058] Referring primarily to FIGS. 2 & 3, a typical panel
assembly 40 comprises a metal composite material (MCM) panel 80
made of two thin sheets of metal 85 sandwiching and laminated to a
synthetic core 90. Alternatively, a panel of any suitable material
can be utilized. Grooves 95 are typically cut into the backside of
the MCM panel 80 the desired distance from the panel's edges. The
flat panel alone is illustrated in section A of FIG. 2. The
portions of the MCM panel 80 from the groove to the respective edge
are turned downwardly to form panel returns 100 that have generally
perpendicular sides relative to the face 105 of the MCM panel 80 as
illustrated in section B of FIG. 2. Extruded panel perimeter frame
members (PE) 110 as shown in section C of FIG. 2 are provided to
form the rigid framework of the panel assembly. The corners of the
PE frame members are typically mitered to mate with each other and
are typically held together by way of an angle corner clip 130,
which is riveted in place. An assembled frame of PE members is
shown in section D of FIG. 2. The PE members 110 are secured around
the perimeter of the formed MCM panel 80 with rivets 115 (or other
mechanical fasteners) as indicated in section E of FIG. 2. Caulk
(not shown) is applied to the ribbed mating surfaces 120 & 125
of the PE members and the corresponding inside surfaces of the MCM
panel to effectively form a water tight seal between the MCM panel
and the PE members. The result is a panel assembly 40 that is
configured to be attached to a frame opening 35 of the subframe
assembly 10 and, in the case of a dry system, do so in a manner
that prevents water from breaching the corresponding joint.
[0059] The panel assemblies 40 are typically fabricated offsite to
a particular set of design specifications that correspond to the
design specifications of the associated subframe assembly 10 and
subframe opening 35. Typically, the subframe assembly 10 is
installed on the building first and then the panel assemblies 40
are secured to the subframe assembly. As shown in FIG. 3, two panel
assemblies attach to each vertically or horizontally extending
frame member 30 or 33. In prior art dry systems, the tolerances to
which the panels and the corresponding subframes have to be built
is extremely tight, such as +-0.125 inches or better. If a panel
assembly of a prior art system varies by more than the allowable
tolerance relative to its associated rectangular frame opening then
the panel assembly typically has to be remade thereby potentially
delaying completion of the prior art wall and increasing the total
cost of a prior art dry system significantly. It can be appreciated
that building entire panel wall systems to tolerances of better
than +-0.125 inches is extremely difficult especially given the
real world variations of constructing a building. In one embodiment
of the dry curtain wall system as described in greater detail
below, the mating surfaces 150 of the subframe members 30 and/or
33, and the associated PE members 110 permit much greater tolerance
variations (up to about +-1 inch), which greatly reduces the
likelihood that panel assemblies 40 will need to be remade due to
tolerance related errors in fabrication of either the subframe
assembly 10 or the associated panel assemblies 40. This increased
tolerance comes due to the fact that there is not a set location,
as in prior art systems, across the mating surface 150 where the
fastener 50 must attach, thus allowing the joint to be moved and
adjust as needed.
[0060] A typical midwall joint between a pair of adjacent panel
assemblies 40 and a horizontal subframe member is illustrated in a
partially exploded cross section in FIG. 3. A midwall joint is the
typical joint utilized in most locations of a curtain wall except
for joints abutting an edge of a building 20 or joints whereat the
curtain wall terminates (as illustrated and discussed below in
reference to FIGS. 4 & 5).
[0061] The horizontal subframe members 33 are connected to the
studs 15 or the building wall/substructure 475 by way of sliding
subframe attachment clips 45 that are secured to the studs with
self tapping fasteners 50. Shims 135 may be used underneath clips
45 between the base of the clip and the underlying
wall/substructure 475 as necessary to help ensure the entire
subframe assembly 10 is plumb when attached to the
wall/substructure 475 by accounting for any variances in the
relative horizontal and/or vertical positions of the
wall/substructure 475.
[0062] A cross sectional or end view of a typical subframe
attachment clip 45 for use with a dry system is illustrated in FIG.
7. The clip 45 comprises a T-shaped end 65 that extends upwardly
generally perpendicularly from one end of a planer base portion 140
of the clip. Typically, the clips 45 are extruded as elongated bar
stock out of 6063 aluminum that is subsequently heat treated to a
T5 condition. The bar stock is cut at about 2-3 inch intervals to
form each individual clip. In the preferred embodiments, no holes
are provided in the base portion as the self-tapping screw
fasteners 50 drill through the base portion 140 as the clip 45 and
subframe member 30 and/or 33 are attached to the corresponding
wall/substructure 475. In variations, however, one or more fastener
holes can be provided in the base portions 140 of the clips 45. The
T-shaped sections 65 of a plurality of clips are slid into
respective upper and lower slots 47 that are provided along the
back side of the subframe member 30 and/or 33. The number of clips
slid into any particular subframe member will vary based on the
length of a particular subframe member and the distance between
connections to the wall/substructure 475 Depending on how the
subframe assembly sections 25 are fabricated, the clips 45 may need
to be slid into the slots prior to the welding of the assembly
section 25 together. For instance, if horizontal subframe members
33 are welded to long vertical subframe members 30 that span
several rectangular frame openings 35 then the clips 45 must be
slid into the slots 47 of the horizontal frame members 33 before
the subframe assembly section 25 is welded together, as the ends of
the horizontal subframe members 33 will be covered. However, if
shorter vertical subframe members 30 are welded to long horizontal
subframe members 33 that span more than one rectangular frame
opening 35 then access to the ends of the horizontal frame members
33 will be available to slide clips 45 therein.
[0063] In certain situations, it may be desirable to add more clips
45 to a particular horizontal subframe member 33 where access to
the ends of the subframe member 33 is no longer possible. In such a
situation the openings to the respective slots 47 in the subframe
members is large enough to allow ingress of clips when the outward
most arm 145 of the T-shaped portion 65 is removed to form a
J-shaped portion at the clip's end. Simply, the J-shaped portion is
hooked into the slot 47, pulled taut against the outermost side of
the respective slot 47 of the subframe member and secured in place
against an underlying wall/substructure 475.
[0064] A cross sectional or end view of a typical subframe member
30 and/or 33 used in one embodiment of the dry system is
illustrated in FIG. 6. The subframe member essentially comprises a
rectangularly-shaped elongated tube that has (i) a flat top mating
surface 150 for coupling with the PE members 110 of the panel
assemblies 40 by way of a water tight gasket 155 and (ii) the
aforementioned pair of T-shaped slots 47 on its opposing bottom
surface 160. The subframe members are typically extruded from 6063
aluminum that is heat treated to a T5 condition, although it can be
fabricated by other methods and materials. As fabricated, the
interior 165 of each subframe member is completely enclosed, and is
breached only by the self tapping lock bar fastener 50 when the
panel assemblies are attached to the subframe members. Accordingly,
any water that manages to leak past the gasket and around the
threads of the lock bar fastener is contained within the interior
of the subframe member and is unable to penetrate into the building
structure therebeneath. Further, if the volume of the water
penetrating into the interior is large enough, the interior behaves
as a gutter directing the water to and out the ends of the member
through weep holes.
[0065] Referring to FIG. 3, the flat mating surface 150 provides a
wide expanse (about 2 inches wide in one embodiment) against which
a bottom side 170 of the PE members 110 abut by way of the
intervening gasket 155 providing locational flexibility from the
longitudinal center axis of the base frame members 30 and/or 33.
This differs substantially from prior art subframe members that
typically included extruded channels in which threaded fasteners
analogous to the self tapping fasteners 50 are received.
Accordingly, the position of the adjacent frame members in the
prior art system must be within a very short distance of the
fastener and its analogous lock bar to ensure that the frame member
and the panel assembly are properly secured to the subframe member.
In contrast, there is no specific side to side location in which
the self tapping fastener of the one embodiment of the dry system
must be secured to the mating surface so long as sufficient space
is provided to one side or the other against which the frame member
can seat. Practically, using prior art dry-type systems the frame
members can vary no more than about .+-.0.125 inches; whereas, the
positioning of the PE members 110 can vary up to and even greater
than .+-.1 inch in one embodiment of the present dry-type
system.
[0066] The gasket material 155 utilized to seal the joint between
the mating surface 150 of the subframe member 30 and/or 33, and the
bottom sides 170 of the PE members 110 is typically a synthetic
rubber compound, such as Santoprene.TM., although other suitable
materials can be used. The large surface area of the gasket and the
fact that it is continuous across the entire width of the subframe
member's mating surface 150 provides for a superior barrier to
water infiltration when compared to the prior art where two
separate gaskets are typically utilized: one on either side of the
analogous lock bar fastener channel. Essentially in the one
embodiment, any water that manages to leak between the interface of
a subframe member 30 and/or 33, and the lock bar 175 can only
theoretically penetrate into the building by traveling (i) along
the entire length of the interface between the bottom surface 170
of the PE member and the top surface of the gasket or (ii)
traveling down the self tapping fastener 50 between the fastener's
surface and the gasket and then along the interface between the
subframe member's mating surface and the bottom surface of the
gasket. Practically, a water breach along either of these arduous
paths is nearly impossible when the frame members and associated
panel assemblies 40 are properly secured to the subframe members 30
and/or 33.
[0067] A cross sectional or end view of a typical PE member 110
that is used in embodiments of the dry system, as well as the wet
system and the rain screen system, is illustrated in FIG. 9. Like
the subframe members 30 and/or 33, the PE members are typically
extruded of 6063 aluminum that is heat treated to a T5 condition,
although other materials or fabrication methods can be used. A
typical PE member 110 comprises a bottom side 170 which interfaces
with the top surface of the gasket 155. Proximate the left end of
the bottom side as viewed in FIG. 9, a pair of triangular ridges
180 extend and point downwardly. When the PE member 110 is secured
in place against the gasket 155, each ridge 180 bites into the
gasket to provide additional protection against water penetration
along the interface between the top surface of the gasket and the
bottom side of the PE member. Proximate the right end of the bottom
side, a short vertical wall 185 extends upwardly joining with the
remainder of the PE member.
[0068] A generally J-shaped portion 190 extends outwardly and
rightwardly of the short vertical wall 185 about midway along its
length. The J-shaped portion in conjunction with a short portion of
the bottom side 170 that extends rightwardly of the short vertical
wall, form a T-shaped slot 195. As discussed below, this slot is
adapted to receive a T-shaped end of an attachment clip 200 (as
shown in FIG. 8) that is used it the wet and rain screen systems.
This T-shaped slot 195 is not utilized in the dry system. Notably,
a triangular ridge 205 extends downwardly from the downwardly
facing surface of the J-shaped portion 190. This ridge is similarly
sized as the ridges 180 extending from the bottom side 170. The
only purpose of this ridge is to ensure the PE member 110 can be
laid flat on a surface with the bottom side being parallel to the
surface when cutting the PE member to a desired length. It is
appreciated that without this ridge the angle of the bottom side
would be canted slightly due to the ridges 180 proximate the left
end of the bottom side, thus causing errors when measuring and
cutting the PE members.
[0069] From the top end of the short vertical wall 185, a
substantially horizontal wall 210 extends leftwardly. This
horizontal wall in combination with the short vertical wall 185 and
the bottom side 170 form a channel 215 (or slot) into which an
accent strip 220 or twist lock plate 390 can be received (see FIG.
20 and 23 respectively) when the PE member is utilized in
conjunction with an rain screen or wet system.
[0070] From the top surface of the horizontal wall 210
approximately midway along the wall a lower corner clip rib 225
extends upwardly. As discussed above, corner clips 130 are used to
hold the mitered corners of adjacent and typically perpendicular PE
members of a particular panel assembly together. A corresponding
upper corner clip rib 230 extends downwardly from opposing
horizontal panel mating wall 235.
[0071] Generally proximate the distal end of the horizontal wall
210, a substantially vertical panel mating wall 240 extends
upwardly therefrom. The vertical panel mating wall directly
interfaces with the down turned perpendicular sides (panel returns)
100 of a panel 80 and is attached thereto by way of rivets 115 or
other mechanical fasteners, at regular intervals along the sides of
the panel assembly 40. The mating surface 120 of the wall is ribbed
to provide channels to accept caulk that is utilized to ensure a
water tight seal between the panel returns 100 and the PE member
110. This is in contrast to known prior art systems that have
substantially smooth mating wall surfaces. It is appreciated that
as pressure is applied between the smooth mating surfaces of a
prior art frame member and the panel perpendicular sidewalls of a
corresponding panel assembly, a significant amount of caulk if not
all in a particular region of the interface, could be squeezed out
between the interfaces. This could eventually facilitate water
penetration behind the curtain wall at this region, especially as
the rivets loosen with age as a result of repeated flexing caused
by wind incident on a panel face 105. The ribs on the mating
surface 120 of the illustrated PE member prevent the caulk from
being squeezed out of the embodiments described herein, thereby
minimizing, if not eliminating, the potential for water penetration
along the interfaces between the PE members 110 and the panel
returns 100.
[0072] Referring back to the horizontal wall 210, a short section
of the wall extends leftwardly (as shown in FIG. 9) to form a panel
stop rib 245. The panel stop rib provides a geometric reference
against which the ends of the down turned perpendicular sides
(panel returns) 100 of panels 80 having down turned perpendicular
sides in excess of about 1 inch in depth can bottom out, and rest
upon. Referring back to FIG. 3, the depth of the down turned
perpendicular sides 100 of the illustrated panels is less than or
equal to 1 inch, and accordingly, do not bottom out against the
panel stop rib 245. However, in variations using panels 80 with
deeper sides 100, the panel stop ribs help ensure that the distance
between the face 105 of the panel and the bottom surface of the PE
member's bottom side 170 is uniform for each and every panel
assembly 40 in a particular curtain wall assembly. In contrast,
several prior art curtain wall systems, have frame members that do
not provide a stop, which make assembling uniform panel assemblies
much more difficult as an assembler must use some external means,
such as a scale or block, to gauge the proper placement of the deep
sided panel against its corresponding frame members.
[0073] Referring back to FIG. 9, at the top (or distal) end of the
vertical panel mating wall 240, the horizontal panel mating wall
235 extends outwardly therefrom. Like the vertical mating wall, the
horizontal mating wall also has a ribbed mating surface 125. This
mating surface performs similarly to vertical ribbed mating
surface. It is to be appreciated; however, that the mating surface
of the horizontal wall will only come in contact with the bottom
surface of a panel's face when the depth of the panel's down turned
perpendicular sides (panel returns) 100 are less than the depth of
the vertical panel mating wall 240 (typically 1 inch or so).
Accordingly, when deep-sided panels are used, this mating surface
125 will not be in contact with the panel 80.
[0074] As shown in FIG. 9, the upper corner clip rib 230 that
corresponds with the lower corner clip rib 225 extends downwardly
from the horizontal panel mating wall 235 at an intermediate
location between its proximal and distal ends. In combination with
the lower corner clip rib 225, the back surfaces of the panel
mating walls and the back surface of the horizontal wall, a slot is
formed in which a corner clip 130 can be received.
[0075] Referring again to FIG. 3, adjacent PE members 110 from
adjacent panel assemblies 40 are placed against a gasket 155 that
has been placed upon the mating surface 150 of an associated
subframe member 30. To secure the PE members and the panel
assemblies 40 (to which they are secured), to the subframe member
30 an/or 33, the elongated lock bar member 175 is placed in the
channel created between the adjacent panel assemblies 40 and
secured in place using a plurality of self tapping fasteners 50
along the length of the lock bar member.
[0076] A typical lock bar member according to one embodiment of the
present dry system is illustrated in FIG. 10. Like the subframe
members 30 and/or 33, and the PE members 110, the lock bar members
are typically extruded of 6063 aluminum that is heat treated to a
T5 condition, although other materials, such as a plastic, or other
fabrication methods can be used. The lock bar members 175 are cut
to various lengths as required and can span between several panel
assemblies 40. As illustrated, the lock bar member 175 is hollow
although in variations it can comprise a solid cross section.
[0077] The bottom side of the lock bar includes two
longitudinally-extending bearing surfaces 250 on either
longitudinal side of the lock bar. The respective left and right
bearing surfaces bear down on the outer edge of the bottom leg 170
of the PE members 110 to secure the PE members in place against the
gasket 155 and subframe members 30 and/or 33. Intermediate the left
and right bearing surfaces on the bottom side, a gasket compression
ridge 255 is provided. The compression ridge 255 extends downwardly
from bearing surfaces 250 and includes a flat bottom surface 260
that compresses directly against the gasket 155. The downward
compression of the gasket in the region directly below the ridge
255 also causes the gasket 155 to compress and seal around the self
tapping fastener 50; thereby, minimizing the potential for water to
seep along the threads of the fastener 50 into the hollow gutter
165 of the subframe members and/or 33. The sidewalls 265 of the
compression ridge serve the additional purpose of providing a
geometric fence for the inside edges of the corresponding PE
member's bottom legs 170 to ensure the PE 110 members and the panel
assemblies 40 are evenly spaced about the lock bar member 175 and
the self tapping fastener 50.
[0078] The top surface 270 of the lock bar member 175 includes a
shallow centrally located v-shaped channel 275 that extends
longitudinally along the top surface of the lock bar to facilitate
accurate drilling of fastener holes therethrough. Further, in the
hollow version of the lock bar, as illustrated, an interior
longitudinally-extending valley 280 or channel is located in the
bottom horizontal surface of the bar's hollow interior to further
assist in drilling aligned fastener holes. These channels help
ensure that the self tapping fasteners 50 enter the lock bar
substantially perpendicularly which in turn helps ensure that even
clamping or bearing pressure is applied to both adjacent PE members
110.
[0079] Along the left and right sides of the lock bar member cover
cap indentations 290 are provided to snappily receive the
respective left and right ends of a cover cap 295 (see FIG. 11)
thereover, to fully enclose the head of the self tapping fastener
50 and provide a finished surface flush with the face 105 of the
panel assemblies. A typical cover cap is illustrated in FIG. 11.
Like the other elongated components of the dry-type curtain wall
system, the cover cap is preferably extruded of aluminum or an
aluminum alloy, although the cover cap can be fabricated by other
means or from other materials such as plastic.
[0080] The illustrated cover cap 295 includes a flat top face 300
that, when installed, is flush with the face 105 of the adjacent
panel assemblies 40; however, variations of the cover cap can have
any desirable face geometry including, but not limited a sloped
face, a rounded semicircular face and a pointed face. A pair of
generally parallel legs 305 extend downwardly from the top face 300
and terminate at inwardly toothed distal ends 310 that interface
with the cover cap indentations 290 on the lock bar members 175.
The teeth 310 on the distal ends are sloped gently inwardly to
facilitate gradual and controlled engagement of the cover cap 295
onto the lock bar 175. At the inside intersection 315 of the top
face 300 and the downwardly extending legs 305 the thickness of the
cover cap is reduced somewhat to facilitate the outward flex and
spring of the legs at this location as the cap is snapped over the
lock bar 175.
[0081] Referring back to FIG. 3 again, cross sections of the legs
of opposing angle corner clips 130 are illustrated. As discussed
briefly above, the angle corner clips 130 join mitered extending PE
members 110 of a particular panel assembly 40 together when the
clips are riveted to the respective PE members as illustrated.
Typical corner clips 130 are illustrated in FIG. 2, section C. The
corner clip can be fabricated from any suitable material such as
aluminum, steel, or a reinforced or unreinforced plastic material.
Caulk is typically utilized around the intersection of the down
turned perpendicular sides 100 to ensure the associated panel
assembly 40 is water tight.
[0082] Referring to FIG. 16, a second type of corner clip 320 is
illustrated in conjunction with an angled panel assembly 325. The
second type corner clip 320 comprises a flat L-bracket and is only
utilized to join PE members of angled panel assemblies together as
would be potentially utilized to cover an inside or an outside
corner of a building. As can be appreciated, the second type of
corner clip 320 is also received into the slot formed by the corner
clip ribs 225 & 230 and the second type corner clip is secured
into place with rivets 115 or other acceptable fasteners.
[0083] A typical joint that would be utilized on an inside corner
is illustrated in FIG. 4. As shown, the ends of the panel
assemblies 40 along a first wall 330 are mounted close to flush
against the corresponding perpendicular second wall 335 of the
inside corner. As shown, a vertical subframe member 30 is secured
to the building a short distance from the location of the faces 105
of the panel assemblies mounted to the first wall 330. As discussed
above, the vertical subframe members 30 are not necessarily secured
to the studs 15 of the building as their locations may not
correspond. However, should a stud be sufficiently close to a
vertical subframe member, the subframe member 30 may be secured to
the stud by way of a plurality of subframe attachment clips 45
riding in one of the subframe attachment clip slots 47 of the
subframe member.
[0084] After the panel assemblies 40 on the first wall 330 have
been installed, an elongated piece of backer rod 340 is stuffed
between the outside face of the first wall panel assemblies and one
side of the vertical subframe member. Caulk 345 is applied over the
backer rod to effectively seal the curtain wall at this inside
corner.
[0085] The panel assemblies 40 concerning the second wall 335 are
attached to the vertical subframe member 30 in a manner
substantially similar to the manner in which the panel assemblies
are attached at a midwall joint except only a single panel assembly
is attached to the subframe member instead of two adjacent panel
assemblies. Because of the expansive mating surface 150 of the
subframe member and the fact that the lock bar member 175 can be
secured to the mating surface anywhere along its width, the same
subframe member can be used at either a midwall joint or a corner
joint not to mention a termination joint (as discussed immediately
below). This is in contrast to several prior art dry systems where
different subframe members must be used depending on whether the
subframe member is located at an outside edge of a particular
subframe assembly or a midwall location.
[0086] Referring to FIG. 5, a typical termination joint is
illustrated for one embodiment of a dry system. Essentially, the
subframe member 30 and/or 33, and the panel assemblies 40 are
attached and joined together in essentially the same manner as the
curtain wall section attached to the second wall 335 of FIG. 4
except (i) a backer rod 340 and associated caulk 345 are used to
seal the bottom side 160 of the subframe member against the
building wall/substructure 475 preferably a stud of the building to
prevent water penetration behind the curtain wall and (ii) a
different cover cap 350 is utilized to present a finished end of
the curtain wall system by covering both the exposed side of the
lock bar member 175 and the subframe member. As is illustrated, the
cover cap shown includes an elongated leg 355 on one side that
extends below its tooth 310, which is configured to snap into the
lock bar member 175. In all other respects, the elongated leg cover
cap is identical to the cover cap 295 discussed above with
reference to FIG. 11.
A First Wet System Embodiment
[0087] As mentioned and discussed above, the extruded PE member 110
of the one embodiment is capable of use in both wet, dry and rain
screen curtain wall systems in contrast to prior art curtain wall
frame members which are typically configured for use in only one or
two types of curtain wall applications. A typical wet system
midwall joint between two panel assemblies 40 is illustrated FIG.
17. Unlike the one embodiment of the dry system, no subframe
assembly is utilized. Rather, the panel assemblies are attached
directly to the building wall/substructure 475 by way of PE member
attachment clips 360 and self tapping fasteners 50 that are screwed
through a base portion 365 of the clips directly into the building
wall/substructure and preferably studs 15. Because the ability of
wet systems to prevent water penetration at the joints is less
certain than well tested dry systems, architects often require that
buildings using wet or rain screen systems including sheathing 415
and a moisture barrier applied over the building studs 15 to offer
a second line of defense against water penetrating into the
building. It is appreciated that the caulking and backer rod used
to seal the wet system may in certain environmental conditions
degrade to the point where water can penetrate through the
joint.
[0088] Referring to FIG. 17, the panel assemblies 40 utilized with
this embodiment of the wet system are the same as the panel
assemblies used with the first embodiment of the dry system. To
attach the panels to a building frame, T-shaped portions 380 at the
ends of PE member attachment clips 360 are slid into respective
T-shaped slots 195 of adjacent PE members 110. The PE attachment
clips 360 are secured to a building wall/substructure 475 using
self tapping fasteners 50. Spacer shims 135 may be utilized between
the studs 15 and the attachment clips 360 as necessary to help
ensure the resulting curtain wall is plumb despite any variations
in the building's studs.
[0089] A typical PE member attachment clip 360 is shown in FIG. 8.
It comprises essentially the same materials as the subframe
attachment clip 45 of FIG. 7 and is similar in configuration having
a T-shaped portion 380 and a planer base portion 365 except the
height of the T-shaped portion 380 of this clip 360 is greater than
the corresponding height of the clip 45 of FIG. 7. Positionally,
along a joint of two panels as shown in FIG. 17, the top and bottom
clips alternate and are staggered to insure that both panel
assemblies 40 are securely fastened to the building
wall/substructure 475.
[0090] To seal a wet system, a piece of backer rod 340, which
typically comprises an open cell foam material, is compressed into
the joint over the self tapping threaded fastener 50 and then caulk
345 is applied over the backer rod to prevent water penetration at
the joint.
[0091] It is to be appreciated that because of the elimination of
the subframe assembly 10, the gasket 155, the lock bar members 175
and the cover caps 295, the wet system is generally much less
expensive to use than its dry system counterpart. However, because
the joints are filled with caulk 345 instead of a cover cap, the
appearance of the joints is typically less desirable and durable
than the dry system. Further, repair and replacement of damaged
panel assemblies 40 require the destruction and eventual
replacement of the joint sealing material, which renders the backer
rod 340 and the caulking unusable. Whereas, with the dry system,
panels can be removed and replaced with relative ease, and although
some cover cap is destroyed in the process, a vast majority of the
cover cap can be reused.
[0092] A typical termination joint for a wet system is illustrated
in FIG. 18. The joint is generally similar to the midwall joint
shown in FIG. 17, yet the edge of the panel assembly 40 is adjacent
and opposite an edge of the building, such as the end of a brick
facade or other material 370. Once the panel assembly is secured in
place, backer rod 340 is compressed between the building end and
the panel end and the remaining space is filled with caulk 345 to
seal the curtain wall system against water penetration.
[0093] A sill termination joint for the wet system is illustrated
in FIG. 19. This joint is primarily used at the base of a building
wall where it abuts against the foundation or sill 420 of the
building. Simply, the PE attachment clip 360 is replaced with a
J-channel member 425 and the T-shaped slot 195 of the PE member 110
is not utilized. The J-channel member is secured to the building
wall/substructure 475 in the same manner as the attachment clips by
way of self tapping screws, yet it is pre-attached to the wall at
the proper elevation prior to the panel assemblies. Once the
J-channel has been installed, the installer places the panel
assembly over the J portion of the J-channel member such that the J
portion is received into the channel 215 of the associated PE
member 110. Accordingly, the panel assemblies 40 rest against and
onto the J-channel member 425. After the panel assemblies 40 are
secured in place, the joint is sealed with backer rod 345 and caulk
345. The use of the J-channel member 245 in place of the PE
attachment clips 360 permits the panel to be placed closer to the
sill because there is no base portion of the PE attachment clip
that must extend beyond the bottom edge of the panel through which
a self tapping screw is received (see FIG. 18 for example.)
Further, the use of the J-channel member 245 makes the installation
of the bottom row of panel assemblies more accurately level, less
complicated and consequently quicker to install because the panels
do not have to be slid along the T-shaped portion of the attachment
clip during installation, or alternatively, the clips do not need
to be preinstalled on the sill side of the panel assemblies, which
would make attachment of the clips to the building
wall/substructure more cumbersome.
A Rain Screen System Embodiment
[0094] A typical rain screen midwall joint between two panel
assemblies 40 is illustrated in FIG. 20. Similarly to the wet
system, no subframe assembly 10 is utilized. The panel assemblies
are attached directly to the building studs 15 by way of PE frame
member attachment clips 360 and self tapping fasteners 50 that are
screwed through a base portion of the clips directly into the
studs. The rain screen system is substantially similar to the wet
system concerning the manner in which it is attached to the studs
of a building. The major difference between the rain screen system
and the wet system is the substitution of an accent strip 220 in
place of the backer rod 340 and caulk 345. As illustrated, the
accent strip 220 resides in the opposing and adjacent channels 215
of two adjacent PE members 110. Additionally, the spacing between
panel edges at a joint can be varied in size with the width of the
accent strip 220; whereas, the spacing in the wet system is limited
by the size of backer rod and caulk that can effectively seal the
joint. The accent strip can comprise any suitable material and may
be rigid, such as when made of aluminum or a rigid plastic, or
flexible, such as when made of an at least partially elastomeric
plastic.
[0095] Typically, the rain screen system is the least expensive to
purchase and install as the additional labor of installing the
backer rod 340 and caulking the joints is eliminated. Further, the
appearance of the rain screen system is usually preferable to a wet
system. However, the rain screen system is not weather proof and
water will easily penetrate behind the panels at the joints.
Accordingly, when used on a portion of a building that is exposed
to the elements, the building must typically be sheathed in
orientated strand board or plywood and covered in a barrier film,
such as Tyvex.TM.. The rain screen system is best utilized on
covered exterior portions of a building where exposure to the rain
and snow is minimized. For instance, a rain screen system may be
used in conjunction with a dry system to save money on the exterior
walls of a building that are covered, such as by an overhang.
A Second Embodiment Dry System
[0096] FIGS. 14, 15 & 24 illustrate a second embodiment dry
system and various components thereof. The second embodiment dry
system utilizes the same subframe members 30 and 33, and the
attachment clips 45 to secure the subframe assembly as the first
embodiment; however, the use of PE members are eliminated and flat
panels 80 are utilized in place of the panel assemblies 40 of the
first dry system embodiment. In other words, the panel assemblies
of the second dry system embodiment are the flat panels.
Advantageously, the second embodiment dry system has a lower
profile than the first embodiment dry system as well as prior art
dry systems.
[0097] Referring to FIG. 24, the subframe members 30 and associated
subframe assemblies are secured to the studs 15 of the building in
the same manner as described for the first embodiment dry system,
and accordingly, this subframe assembly embodies many of the same
advantages as the subframe assembly of the first embodiment dry
system.
[0098] A gasket 155 is placed over the top surface 150 of the of
the subframe member and the edges of MCM or other suitable panels
40 are placed on top of the gasket proximate the left and right
edges of the subframe member with typically 0.5'' or more of the
bottom surface of each panel being in direct contact with the top
surface of the gasket 155. Top gasket strips 480 are placed on the
top surface of the portion of the panels that overlap the subframe
member. These gasket strips are preferably made of the same
material as the wider gasket 155. To compress both types of gaskets
against the respective top and bottom surfaces of the panel 40, a
wide lock bar member 430 is utilized.
[0099] The wide lock bar members 430 are typically extruded from
6063 aluminum that is heat treated to a T5 condition, although it
can be fabricated by other methods and materials. The cross section
of the wide lock bar is illustrated in FIG. 14. The wide lock bar
comprises a top surface 455 and a center channel 450 that extends
longitudinally down the center of the wide lock bar. The center
channel is of sufficient width and depth to receive a button head
self-tapping screw 470 therein, as well as, a cover cap 460 and its
associated toothed interlocking legs 465. The sidewalls 435 of the
center channel are recessed and configured to lockably receive the
toothed legs of the cover cap therein. The cover cap 460, which is
typically but not necessarily comprised of 6063-T5 an aluminum
alloy, is illustrated in FIG. 15. As shown in FIG. 24, the top
surface of the cover cap is typically flush with the top surface of
the wide lock bar member, although in variations the cover cap and
the top surface of the wide lock bar member can have any number of
different configurations to provide a desired aesthetic look.
Further, the depth of the channel can vary to permit screws or
fasteners with thicker heads to be fully contained in the
channel.
[0100] Still referring to FIG. 14, proximate the left and right
edges of the wide lock bar member 430 on either side of the center
channel are left and right underside surfaces 485 that are located
vertically above the underside surface of the center channel 440.
The approximate vertical distance between each of the left and
right underside surfaces and the underside surface of the center
channel is equivalent to the thickness of an associated panel 40
plus the thickness of a top gasket strip. Accordingly, as shown in
FIG. 24, the panel is compressed between the top surface of the
wider gasket 155 and the bottom surface of the corresponding gasket
strips 480 to effectively seal the corresponding interfaces against
water penetration. To further eliminate the possibility of water
penetration, several longitudinal triangular ridges 445 are
provided on the left and right underside surfaces 485. As also
shown in FIG. 24 the underside surface of the center channel is
compressed against the top surface of the wider gasket 155 to
prevent any water that may have seeped into the center channel and
along the fastener hole from traveling outwardly towards the
interface between the top surface of the wider gasket 155 and the
bottom surface of the panel and eventually into the building.
Further, the compression of the gasket 155 under the center channel
causes the gasket material to seal around the fastener 470 as it
passes therethrough minimizing the amount of water traveling along
the surface of the fastener. However, as described above, any water
that does penetrate into the subframe member via the fastener is
channeled away from the building along the hollow interior of the
subframe member.
[0101] It is to be appreciated that numerous variations of the
second embodiment dry system are contemplated. For instance, the
configuration of the wide lock bar and its associated cover cap can
vary substantially and still effectively sandwich a flat panel 40
between two gasket surfaces to prevent water penetration into the
building. In other variations, the number of triangular ridges can
vary and the ridges can be provided on other surfaces of the wide
lock bar to further inhibit water penetration. In yet other
variations, the subframe member 30 can include longitudinal
triangular ridges along its top surface 150 in various desired
locations.
A Second Embodiment Wet System
[0102] FIGS. 13 & 23 illustrate a second embodiment wet system
and its associated twist lock plate 390. The second embodiment wet
system, hereafter referred to as the twist lock system, utilizes
the same or similar panel assemblies 40 as the first wet system but
rather than being attached to the building wall/substructure 475
using the sliding PE attachment clips 360 of the first wet
embodiment, twist lock plates 390 are lockably received in the rain
screen channel 215 and fastened to the building with self threading
fasteners 50, thus anchoring the panel assemblies to the building
wall/substructure 475. As will be shown, one benefit and novelty of
this embodiment is that it allows a wet system to be attached and
installed in a non-sequential fashion, whereas in prior art systems
all wet systems are sequentially installed.
[0103] Referring to FIG. 23, a typical midwall joint of the twist
lock system is illustrated. The outer edges of the twist lock plate
390 are simultaneously braced against the short vertical walls 185
of the opposing PE members. Accordingly, the left panel is
prevented from moving rightwardly and the right panel is prevented
from moving leftwardly. Considering that all sides of a typical
panel would be secured in a similar manner, the panel is
effectively locked in place to prevent planar movement. As further
illustrated, the twist lock plate further acts to clamp the panel
assemblies in place against spacer shims 135, which are typically
braced against the sheathing or other part of the building
wall/substructure 475 with the clamping force provided by a
self-tapping screw 50 that passes through the center of the twist
lock plate and is typically fastened into the sheathing 415 and/or
a stud 15. In variations of the second embodiment wet system, the
spacer shims 135 need not be utilized and the bottom surface of the
PE member's bottom side 170 can be braced directly against the
sheathing or rain barrier material that covers the sheathing.
[0104] Referring to FIG. 13 illustrates a top view of the twist
lock plate 390. The twist lock plate is typically comprised of
either steel or aluminum alloy plate that has been cut into a
roughly rectangular shape with two generally parallel opposing
longitudinal sides. A circular opening 395 is provided midway along
the longitudinal axis of the plate. The opening is sized to receive
the shank of the threaded self tapping fastener 50 therethrough.
The short dimension of the generally rectangular shape is such that
the twist lock plate will fit within the joint created between two
adjacent panel assemblies. The left and right ends intersect with
the longitudinal sides and each end includes a perpendicular
portion that intersects with a respective longitudinal side at a
sharp 90 degree angle 405 and a canted portion 400 that intersects
with the other longitudinal side along a radius to form an obtuse
angle. As shown, the canted portion of the left end intersects with
the top longitudinal side and is cattycorner with the right end's
canted portion, which intersects with the bottom longitudinal
side.
[0105] In use, an installer places the twist lock plate, with a
fastener 50 pre-inserted into the plate's opening 395,
longitudinally into the joint opening between two adjacent panel
assemblies 40. The twist lock plate and fastener are centered
within the joint, and the fastener is driven into place by the
installer. As the fastener is tightened, the twist lock plate 390
is pulled deeper into the panel joint, and eventually reaches the
channels 215 within the PE 110. Once the plate reaches this depth
within the joint, the plate can rotate clockwise within the
channels 215 because of the geometry of the canted portions of each
end of the twist lock plate. The right and left ends of the twist
lock plate 390 are received into the left and right channels 215
respectively of the PE members 110. The canted portions of each end
of the twist lock plate allow the plate to rotate and not impact
the PE channels vertical wall 185, yet the plate will stop rotating
once the non-canted portions of each end impact this vertical wall
185 and the PE channel 215. It is appreciated that the sharp corner
intersection 405 between the perpendicular portions of the right
and left ends, and the longitudinal sides, prevents further
rotation of the plate. To remove and replace a damaged or defective
panel assembly, an installer need only remove the fasteners and
associated twist lock plates on all four corners of the panel
assembly and pull the panel away from the building. The new panel
assembly is simply dropped in place and fasteners and twist-lock
plates are reinstalled.
[0106] In variations of this embodiment, the shape and
configuration of the twist lock plate can vary substantially as
would be obvious to one of ordinary skill in the art with the
benefit of this disclosure. Further, the configuration of the PE
members 110 can vary. For instance, PE members without the t-shaped
slots can be provided as the wet system attachment clips of the
first embodiment are not utilized.
[0107] Various elements of both wet system embodiments can be used
together. For instance, the J-channels 425 could be used to secure
the panel assemblies to the bottom of a wall proximate the
building's sill as shown in FIG. 19 in conjunction with the use of
the twist lock plates 390 for mid-wall joints as shown in FIG. 23.
Further, the J-channel connectors can also be used at other
termination joints as the point of contact between the J-channel
and the PE member of a panel assembly provides a rigid connection
against which the panel assembly can be wedged in place by way of
pressure provided from the opposite and opposing side of the panel
assembly from the twist lock plates 390.
Other Embodiments and Variations
[0108] The various preferred embodiments and variations thereof
illustrated in the accompanying figures and/or described above are
merely exemplary and are not meant to limit the scope of the
invention. It is to be appreciated that numerous variations to the
invention have been contemplated as would be obvious to one of
ordinary skill in the art with the benefit of this disclosure. All
variations of the invention that read upon the appended claims are
intended and contemplated to be within the scope of the
invention.
[0109] In the first dry system, the PE members of the panel
assemblies are extruded of an aluminum alloy; however, in
variations and alternative embodiments, the PE members can be cast
or forged. Further, the PE members can be comprised of a reinforced
or unreinforced polymeric material. Similarly, the other aluminum
components can be comprised of other metals or polymeric materials
and can be fabricated using any suitable processes. The panels as
described above are typically aluminum faced panels with plastic
cores, although in variations and alternative embodiments, the
panels can be comprised of a single material ( for example metal,
plastic or glass) or they can comprise suitable different materials
then specifically described above.
[0110] The actual configurations of the various components of both
systems can vary substantially as well such that variations can
have substantially differing cross sections than the components
illustrated herein but serve the same function and read upon the
appended claims. For instance in an alternative embodiment of the
subframe members, the subframe attachment clips can include a slot
that interfaces with an appendage extending from the subframe
member. In yet other embodiments, the subframe members can be
tubular but have flanges instead of slots for subframe attachment
clips. In yet another variation, the subframe member may not be
tubular but may include slots or appendages for receiving subframe
attachment clips. Concerning the panel assembly PE members, for
instance, some PE members may dispense with the slots for the
associated attachment clips that are used in one embodiment of the
wet system.
* * * * *