CARBON REDUCING CURTAIN WALL STRUCTURE

Abstract

A curtain wall includes a frame made of an organic recyclable material. A fiber reinforced material is affixed to an exterior facing surface of the frame. An anchor is affixed to a non-exterior facing surface of the frame and fiber reinforced material. A gasket is disposed in at least an exterior facing surface of the fiber reinforced material, A window is affixed to the gasket. A cavity is formed between the window, the fiber reinforced plastic and the anchor. Structural silicone is disposed within the cavity in sealing contact with window, the fiber reinforced material and the anchor.

Description

FIELD OF INVENTION

The invention disclosed herein relates generally to a unitized curtain wall for use in assembling a commercial building, house or similar structure, and more specifically to a curtain wall for supporting a window therein while minimizing the net carbon effect on the environment.

BACKGROUND OF THE INVENTION

It has become desirable to reduce the carbon footprint in most activities, particularly the construction and use of housing. As is known in the art curtain walls are used in the manufacture of commercial buildings, houses and other dwellings. Prior art curtain walls are decorative outer coverings and are nonstructural; designed to improve the aesthetics of a building or a house. It is known for the curtain wall to support one or more glass plates, forming windows, therein. However, because curtain walls are considered to be nonstructural, the mullions (spaced window support structures) are made of lightweight materials such as aluminum to reduce shipping weight and facilitate on sight construction. During use, the curtain wall carries no structural load beyond its own dead weight and window load considerations based on building decision criteria.

As is known in the art, aluminum mullions carry no weight, because they cannot carry a load much beyond their own weight; no deadload capabilities. Additionally, they have an R-value of 0.09 ft2° F. hr/Btu; in effect they are thermal conductors, not insulators; requiring additional energy to cool or heat the building interior, as well as the need for additional insulating structure. Furthermore, aluminum is a non-biodegradable material requiring intensive energy to manufacture and recycle. It has a negative net effect on the environmental carbon cycle. It adds carbon and other pollutants to the atmosphere.

Accordingly, a system which overcomes the shortcomings of the prior art is desired.

SUMMARY OF THE INVENTION

A unitized curtain wall includes a frame made of an organic recyclable material. A fiber glass reinforced material is affixed to an exterior facing surface of the frame. An anchor is affixed to a non-exterior facing surface of the frame and fiber reinforced material. A gasket is disposed on at least an exterior facing surface of the fiber reinforced material, A window is affixed to the gasket. A cavity is formed between the window, the fiber reinforced material and the anchor. Structural silicone is disposed within the cavity in sealing contact with the window, the fiber reinforced material and the anchor.

In one embodiment of the invention, the window is a glass window and is laid upon the gasket. The frame is formed of wood and more preferably glue laminated timber (“glulam”). The anchor is a male anchor having hooks extending therefrom in a direction away from the frame. The glass is a vacuum insulated glass.

In another embodiment a wall is formed by affixing the unitized curtain wall to a second unitized curtain wall. The second curtain wall having a female anchor to affix a first curtain wall having a male anchor to the second curtain wall; having the female anchor in side by side relation.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is better understood by reading the written description with reference to the accompanying drawings and figures in which like reference numerals denote similar structure and refer to the elements throughout, in which:

FIG. 1 top down sectional view of a male curtain wall mullion constructed in accordance with the invention; and

FIG. 2 top down sectional view of a female curtain wall mullion constructed in accordance with the invention;

FIG. 3 is a top sectional view of a male curtain wall mullion and a female curtain wall mullion affixed to each other in accordance with the invention; and

FIG. 4 is a top down sectional view of a curtain wall mullion constructed in accordance with another embodiment of the invention . . .

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The subject matter of aspects of embodiments of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of any patent issuing from this description. Rather, the inventor has contemplated that the claimed subject matter might also be embodied in other ways, to include different elements or combinations of elements similar to the ones described in this document, in conjunction with other present or future technologies.

As seen from FIG. 1, a curtain wall generally indicated as 10 includes a frame 6. In a preferred non limiting embodiment frame 6 is formed of organic material, preferably wood. In the preferred non limiting embodiment of the invention frame 6 is formed of a glulam having two or more wood beams 6a-6n affixed to each other as known in the art. When in place during use frame 6 extends from an exterior facing surface 16a of beam 6a to which the remaining structure is attached to an interior facing portion 6n of the curtain wall 10. As will be discussed below, by using glulam materials as the frame 6, the environmental impact of curtain wall 10 is reduced while improving structural integrity and load bearing capabilities.

A fiber reinforced material 4 is affixed to the exterior facing surface 16 of frame 6 by an adhesive, or mechanical means, such as a screw or the like. A gasket 3 is disposed to an outward facing, exterior surface 14 of fiber reinforced material 4. It should be noted that in a preferred non limiting embodiment, fiber reinforced material 4 may be formed of several layers secured together by adhesive, or a mechanical device such as screw 25. Furthermore gasket 3 may extend from outward facing, exterior surface 14 to along a side of fiber reinforced material 4.

In a preferred non limiting embodiment a window 1 is mounted against gasket 3. A male anchor 5 for securing adjacent curtain walls to each other is affixed to a lateral, not exterior or interior facing, side of frame 6 by a fastener, such as screw 27, in a preferred embodiment. Anchor 5 may be affixed to frame 6, by nails, glue, or other adhesive as well. Anchor 5 includes a plate 52c with at least a first fastener 52a extending therefrom, and in a preferred embodiment, at least a second fastener 52b extending therefrom, each extending in a direction away from frame 6. In a preferred non limiting embodiment plate 52c extends from along frame 6 to window 1.

A cavity 30 is formed between glass 1, fiber reinforced material 4 and anchor 5. A structural silicone 2, is disposed within cavity 30 and secures glass 1 to fiber reinforced material 4 and to anchor 5. An additional structural silicone 12 disposed between a lateral edge of window 1 secures window 1 to anchor 5. In an alternative embodiment, a gasket may be used to attach to anchor 5 and form a bulb gasket interface with the glass to facilitate fabrication.

Reference is now made to FIG. 2 in which a female curtain wall 110, constructed in accordance with the invention is provided. The difference between curtain wall 10 and curtain wall 110 is the left-handed orientation of the anchor and the use of a female anchor for illustrative purposes. It should be noted that the structure shown in FIG. 2 as curtain wall 110 may be a stand alone structure, or may be the opposed side of curtain wall 10. In other words a single curtain wall would have a male anchor on one side and a female anchor on another.

Curtain wall 110 is the mirror image of curtain wall 10 and like structure is indicated with like numerals. The primary difference being that a cavity 130 is formed between window 1, fiber reinforced material 4 and anchor 17. A structural silicone 20 having the same properties as silicone 2 is disposed in cavity 130. Similarly, a silicone 120 secures window 1 to anchor 17.

Anchor 17 is formed with a recess 17a and fasteners 17b and 17c formed on respective opposed sides thereof while providing clearance into recess 17a. During use to secure adjacent curtain walls 10, 110 anchor 5 is received in anchor 17 and movement is prevented by first fastener 52a extending into anchor 17 to be secured by fastener 17b and second fastener 52b extending into anchor 17 to be secured by fastener 17a. See FIG. 3. In this way adjacent curtain walls are prevented from moving.

Reference is now made to FIG. 4 in which a curtain wall, generally indicated as 400, constructed in accordance with a second, preferred embodiment of the invention is provided. In a preferred nonlimiting embodiment curtain wall 400 includes a frame 410. A substantially “T” shaped groove 450 is formed within frame 410. Again frame 410 is formed of organic material, preferably wood. Frame 410 may be formed as a single structure or the adjoining of two pieces as discussed above. As with the previous embodiment, when in place during use, frame 410 extends from an interior facing surface 412 to an exterior facing surface 414.

T-shaped groove 450 extends from exterior facing surface 414, internally to a head of the T shaped groove 460. An extrusion in the form of knife plate 456, is disposed along exterior surface 414 of frame 410. Knife plate 456 includes a removeable stop 458 extending from a base of knife plate 456. A body 459, preferably hollow of knife plate 456 extends in a direction away from exterior surface 414. A gap 426 is formed between removeable stop 458 and body 459.

An anchor 452 extends in an interior direction from, and may be integrally formed as part of, knife plate 456. Anchor 452 extends to a “T” head 454 to form an overall T shaped anchor. The T shaped anchor is sized and shaped to be received by T shaped groove 450. In a preferred non limiting embodiment, knife plate 456, including anchor 452 is extruded, and preferably extruded aluminum. T shaped anchor 452 is slidably received within groove 450.

It should be noted that any engaging mating shape, such as a “J” by way of non-limiting example may be used, but the “T” is the preferred non limiting example. The use of “T” anchor 452 provides engineered pull out capacity Quality Assurance Quality Control requirements to manufacture a warrantable air and water seal. Knife plate 456 is preferably made of extruded aluminum a non-limiting embodiment, but may also be formed of fiber reinforced plastic

A gasket 472 is disposed along the height and top surface (exterior facing) of removable stop 458. A gasket 480 is disposed along a portion, and preferably coextensive with, the exterior facing surface of body 459. Gasket 480 may extend to a gasket overhang 470 is disposed to extend beyond an edge of knife plate 456 and may descend along the body of knife plate 456 from overhang 470 towards frame 410.

A structural silicon 430 is disposed within gap 426 and engages and secures vacuum insulated glass 1, the glass 1 enclosing gap 426, to frame 410 and gasket 480 and abutting removeable stop 458.

In the preferred non limiting embodiment, the mass timber unitized curtain wall described above dramatically reduces energy loss through fenestration. The structure, in a preferred non limiting embodiment, uses structural silicone (R8-R22 ft2° F. hr/Btu) to anchor tempered vacuum insulating glass VIG (R8-R22 ft2° F. hr/Btu) to an extruded knife plate or fiber reinforced plastic FRP (R-value 2.2-3.8 ft2° F. hr/Btu) spacer with which is affixed to a thermal resistant mass timber frame (R-value 2.2 ft2° F. hr/Btu). This replaces the prior art aluminum frame (R-value 0.09 ft2° F. hr/Btu), the insulative affects increase, reducing energy usage while providing additional structural strength and integrity.

Both embodiments of the structure lend themselves to simple manufacture. In the preferred embodiment, frame 410 may simply be jig sawed or routed. Alternatively frame 410, may be formed as a carved left half and a carved right half, each formed with half the “T” and then glued together. The extruded knife plate 456 is then formed and slid into place within the formed groove 450. Gaskets 472, 480 are attached to the knife plate 456; before installation if desired. The silicon 430 is deposited in gap 426. Glass pane 1 is then placed on the gasket 480, held in place by silicon 430.

The first embodiment, structure also lends itself to simple manufacture. The glulam material, fiber reinforced plastic material and trim pieces are premanufactured. The structure is manufactured by placing the glulam pieces into an assembly table in a squared orientation. The fiber reinforced plastic material are placed onto the squared glulam piece. A compressed air gun may be used to assemble the glulam frame, and anchor the fiber reinforced plastic material for structural silicone glazing. A gasket is attached to cover the exposed edges of the fiber reinforced plastic material. The glass pane is then placed on the fiber reinforced plastic material and gasket. Structural silicone is then applied between the fiber reinforced plastic material and vacuum insulated glass.

As can be seen below, the curtain wall lends itself to a unitized structure. A unitized curtain wall is a type of curtain wall system that is pre-assembled and delivered to the construction site in modular units, which are then connected to from the building's exterior wall. These units typically consist of a frame made of aluminum or steel, glazing, and insulation, and are manufactured in a factory under controlled conditions. Unitized curtain wall systems are often used in tall buildings because they allow for faster installation and can be more cost-effective than traditional stick-built curtain wall systems. They also offer improved quality control and can be designed to be more energy-efficient and provide better thermal performance.

The timber as it grows sequesters carbon and brings the net embodied carbon of the window system to below net zero. This is in contrast to the aluminum structure requiring massive amounts of energy (carbon) to manufacture, while never being capable of sequestering carbon. Additionally fewer materials are needed with the inventive mullions described above. Aluminum mullions have no deadload capabilities. In contrast thereto mullions using 3″×8″ glulam or unitary wood beams, constructed in accordance with the invention can literally hold up a roof, providing window functionality that is not possible with any aluminum curtain wall. Additionally, the wood frames are made from a sustainable material which pulls carbon and other pollutants from the atmosphere as it grows.

The foregoing description is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will be readily apparent to those skilled in the art, it is not desired to limit the invention to the exact construction and process shown as described above. Accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention as defined by the claims that follow.

Claims

1. A curtain wall comprising: a frame made of an organic recyclable material;a knife plate affixed to an exterior facing surface of the frame; the knife plate including an anchor extending away from the reinforced material into the frame, the anchor being configured to secure the knife plate to the frame;a gasket disposed along the knife plate;a glass sheet disposed on the gasket;a cavity, formed between the window and the knife plate; anda structural silicone disposed within the cavity in sealing contact with window and the knife plate.

2. The curtain wall of claim 1, further comprising a groove formed therein, the groove receiving the anchor therein; securing the anchor to the frame.

3. The curtain wall of claim 2, wherein the groove has a substantially T shape.

4. The curtain wall of claim 3, wherein the anchor has a substantially T shape.

5. The curtain wall of claim 1, wherein the knife plate includes a removeable stop extending from a base of knife plate and a body spaced from the removeable stop; the cavity being formed between the removeable stop and the body.

6. The curtain wall of claim 1, wherein the knife plate is formed form extruded aluminum.

7. The curtain wall of claim 1, the sheet of glass being a vacuum insulated glass.

8. A curtain wall comprising: a frame made of an organic recyclable material;a fiber reinforced material affixed to an exterior facing surface of the frame;an anchor affixed to a non-exterior facing surface of the frame and the fiber reinforced material;a gasket disposed along at least an exterior facing surface of the fiber reinforced material;a window affixed to the gasket;a cavity is formed between the window, the fiber reinforced plastic and the anchor; anda structural silicone disposed within the cavity in sealing contact with window, the fiber reinforced material and the anchor.