The present disclosure generally relates to curtain walls for buildings and, more specifically, to curtain walls having expansion joints configured to permit deflection of the floor structures of buildings.
A curtain wall is an outer covering of a building that spans multiple floors. A curtain wall is non-load bearing in that it does not carry the structural load of the building, other than its own dead weight. As curtain walls are non-load bearing, they may be fabricated from lightweight materials to reduce construction costs. Curtain walls may be designed to keep weather out by resisting air and water infiltration into the building. Furthermore, curtain walls may be designed to accommodate thermal expansion and contraction, and to absorb building sway induced by wind and/or seismic forces. Loads that are imposed on a curtain wall may be transferred to the building through floor anchors that connect the curtain wall to the floor structures of the building.
A curtain wall may be composed of a frame formed from a plurality of horizontal and vertical members. The horizontal and vertical members of the frame may connect to form frame units that receive infill panels of an infill material such as glass, metal, or stone veneer. The vertical members of the frame may be formed from vertical mullions, and the horizontal members of the frame may be formed from transoms or horizontal mullions. The vertical mullions and the horizontal mullions may be formed from a lightweight material, such as extruded aluminum. The vertical and horizontal mullions may assemble with gaskets and pressure plates to create a glazing pocket configured to capture and form a seal with the infill panels. Curtain walls may be characterized as “mullion drained” in which water drainage and ventilation may occur in grooves along the face of the vertical mullions. By contrast, in “zone drained” curtain walls, each infill panel may drain individually so water cannot drain along the lengths of the mullion. In addition, curtain walls may be characterized as “stick” or “unitized” systems. In stick systems, assembly of the frame and glazing (installation of the infill panels) may performed on-site, whereas in unitized systems, frame assembly and glazing is performed at a factory and the fully assembled curtain wall is subsequently erected on the building.
Although current curtain walls are effective, changing practices in building construction are leading to floor structures with deflection limits that are higher than what existing curtain walls may be able to accommodate. For instance, one existing curtain wall design only permits ±2 millimeters of movement, well below the deflection limits of the floor structures of some modern buildings. Other curtain wall systems allow for more movement of the floor structures, but are not widely implemented in practice due to their high costs.
Thus, there is a need for cost-effective curtain wall systems that accommodate the higher deflection limits of the floor structures in some building designs.
A first embodiment of an expansion joint configured to connect first and second vertical mullions of a curtain wall is disclosed. The first and second vertical mullions may each include an elongated body having an inner contour defining a hollow slot and an infill support tongue extending from a side of the elongated body. The first and second vertical mullions may include an inner sleeve extending through the hollow slot of both the first and second vertical mullions. The expansion joint may comprise a body having sides, an upper surface, and a lower surface. The expansion joint may further comprise an inner contour defining a central inner slot extending through the body from the upper surface to the lower surface, and the central inner slot may be configured to receive the inner sleeve therethrough. The expansion joint may further comprise a first raised lip projecting from the lower surface of the body, and a second raised lip projecting from the upper surface of the body. The first raised lip may be configured to insert inside of the inner contour of the first vertical mullion, and the second raised lip may be configured to insert inside of the inner contour of the second vertical mullion.
In a further embodiment of the expansion joint, the expansion joint may be formed from a polymeric elastomer foam.
In another further embodiment of the expansion joint, the expansion joint may additionally and/or alternatively be formed from a closed cell ethylene propylene diene monomer (EPDM) foam rubber sponge.
In another further embodiment of the expansion joint, the first raised lip and the second raised lip may each circumscribe the central inner slot.
In another further embodiment of the expansion joint, the inner contour defining the central inner slot may have a shape corresponding to an outer contour of the inner sleeve.
In another further embodiment of the expansion joint, the first raised lip may be additionally and/or alternatively configured to form an interference fit with the inner contour of the first vertical mullion, and the second raised lip may be additionally and/or alternatively configured to form an interference fit with the inner contour of the second vertical mullion.
In another further embodiment of the expansion joint, the expansion joint may additionally and/or alternatively comprise a projection extending from one of the sides of the body, and the projection may be configured to be inserted between the infill support tongues of the first and second vertical mullions when the expansion joint is assembled with the first and second vertical mullions.
In another further embodiment of the expansion joint, the expansion joint may additionally and/or alternatively include a tab on either side of the projection, and the tabs may extend from the side of the body that includes the projection.
In another further embodiment of the expansion joint, the expansion joint may additionally and/or alternatively include a support rod extending through at least one of the projection and the tabs.
A first embodiment of a curtain wall for a building having floor structures is disclosed. The curtain wall may comprise a frame anchored to the floor structures, and the frame may include a plurality of frame units composed of horizontal and vertical members. The curtain wall may further comprise infill panels supported by the frame units, and vertical mullions forming the vertical members. Each of the vertical mullions may include an elongated body having an inner contour defining a hollow slot, an infill support tongue extending from a side of the elongated body and assembled with a thermal break, and a gasket along the side of the elongated body. The curtain wall may further comprise an inner sleeve inserted through the hollow slots of an adjacent pair of the vertical mullions, and an expansion joint connecting the adjacent pair of the vertical mullions. The expansion joint may include a body having sides, an upper surface, and a lower surface. The expansion joint may further include an inner contour defining a central inner slot receiving the inner sleeve therethrough, a first raised lip projecting from the lower surface of the body and inserted inside of the inner contour of a first vertical mullion of the adjacent pair of the vertical mullions, and a second raised lip projecting from the upper surface of the body and inserted inside of the inner contour of a second vertical mullion of the adjacent pair of the vertical mullions. The expansion joint may be formed from a compressible elastomeric material that allows the adjacent pair of the vertical mullions to accommodate deflection of the floor structures.
In a further embodiment of the curtain wall, the expansion joint may be formed from a closed cell ethylene propylene diene monomer (EPDM) foam rubber sponge.
In another further embodiment of the curtain wall, the expansion joint may be configured to allow the adjacent pair of vertical mullions to accommodate about ±15 millimeters of deflection of the floor structures.
In another further embodiment of the curtain wall, the curtain wall may additionally and/or alternatively include pressure plates assembled with the first and second vertical mullions, and a pressure plate expansion unit between the pressure plates. The pressure plate expansion unit may be formed from a compressible material that allows the adjacent pair of vertical mullions to accommodate the deflection of the floor structures.
In another further embodiment of the curtain wall, the expansion joint and the pressure plate expansion unit may be formed from a closed cell ethylene propylene diene monomer (EPDM) foam rubber sponge.
In another further embodiment of the curtain wall, the expansion joint and the pressure plate expansion unit may be configured to allow the adjacent pair of the vertical mullions to accommodate about ±15 millimeters of movement.
In another further embodiment of the curtain wall, the first and second vertical mullions may each additionally and/or alternatively include an outer sleeve received in the hollow slot of the vertical mullion between the inner contour of the vertical mullion and the inner sleeve. The first raised lip of the expansion joint may be inserted between the inner contour of the first vertical mullion and the outer sleeve of the first vertical mullion. The second raised lip of the expansion joint may be inserted between the inner contour of the second vertical mullion and the outer sleeve of the second vertical mullion.
In a further embodiment of the curtain wall, the expansion joint may additionally and/or alternatively include a projection extending from one of the sides of the body, and a tab on either side of the projection. The tabs may be inserted between the gaskets of the first and second vertical mullions.
In a further embodiment of the curtain wall, the expansion joint may additionally and/or alternatively include a support rod extending through at least one of the projection and the tabs.
In a further embodiment of the curtain wall, the expansion joint may be positioned at a level of one of the floor structures.
A first embodiment of a method of assembling vertical mullions of a curtain wall using an expansion joint is disclosed. The expansion joint may include a body, a central inner slot extending through the body, a first raised lip projecting from a lower surface of the body, and a second raised lip projecting from an upper surface of the body. The method may comprise inserting a first end of an inner sleeve into an inner slot of a first outer sleeve, inserting a second end of the inner sleeve through the central inner slot of the expansion joint, sliding a first vertical mullion over the first outer sleeve, and fitting the first raised lip of the expansion joint into an inner contour of the first vertical mullion. The method may further comprise inserting the second end of the inner sleeve into an inner slot of a second outer sleeve, sliding a second vertical mullion over the second outer sleeve, and fitting the second raised lip of the expansion joint into an inner contour of the second vertical mullion.
These and other aspects and features of the present disclosure will be more readily understood when read in conjunction with the accompanying drawings.
Referring now to the drawings, and with specific reference to
The curtain wall 10 may include a frame 16 anchored to the floor structures 14, and the frame 16 may be composed of a plurality of frame units 18 that support infill panels 20. The infill panels 20 may be panels of an infill material such as, but not limited to, glass, metal, or stone veneer. The frame 16 may be composed of a plurality of vertical members 22 and horizontal members 24 that interconnect to form the frame units 18. The vertical members 22 may include vertical mullions 26 (see
The vertical mullions 26 disclosed herein may be split (or divided into separate pieces) at each of the floor structures 14. Connecting the split vertical mullions 26 at each of the floor structures 14 may be an expansion joint 28 (also see
Turning now to
The vertical member 22 may form a portion of a glazing pocket 56 that receives and forms a seal with one of the infill panels 20. Namely, the glazing pocket 56 of the vertical member 22 may include the gaskets 42, the infill support tongue 44, the thermal break 46, the gaskets 50 of the pressure plates 48, the pressure plates 48, and the pressure plate expansion unit 54.
The expansion joint 28 is shown in isolation in
The expansion joint 28 may have a body 58 that includes sides 60, an upper surface 62, and a lower surface 64. The shape of the body 58 may correspond to the outer shape of the vertical mullions 26. For instance, the body 58 may have a rectangular shape as shown, although it may have other shapes as well in alternative arrangements. An inner contour 66 of the expansion joint 28 may define a central inner slot 68 that extends through the body 58 from the upper surface 62 to the lower surface 64. The central inner slot 68 may be configured to receive an inner sleeve 70 therethrough when the expansion joint 28 is assembled with the vertical mullions 26 (see
The expansion joint 28 may also include a projection 76 extending from one of the sides 60 of the body 58 and along a height (h1) of the expansion joint 28 from the upper surface 62 to the lower surface 64 (see
The height (h1) of the expansion joint 28, as measured from the upper surface 62 to the lower surface 64, may be selected so that the expansion joint 28 is compressible enough to accommodate the deflection limits of the floor structures 14. As a non-limiting example, if the expansion joint 28 is formed from a closed cell EPDM foam rubber sponge, it may have a height of about 80 millimeters to accommodate about 1-15 millimeters of movement of the floor structures 14. In such an arrangement, the first and second raised lips 72 and 74 may have a height (h3) of about 10 millimeters, and the body 58 may have a width (w1) of about 65 millimeters. It will be understood, however, the expansion joint 28 may have other heights depending on such factors as the material that it is fabricated from, the building floor structure deflection limits, and/or the dimensions of the other components of the vertical member 22.
Other dimensions of the expansion joint 28 may be variable to suit the dimensions of the components of the vertical member 22. For example, a depth (d1) of the expansion joint 28 may be selected to compliment or match the depth of the vertical mullions 26 (see
In an alternative arrangement shown in
Turning now to
A method of assembling the expansion joint 28 with the first and second vertical mullions 80 and 82 will now be described. Referring first to
Turning to
The assembly of the expansion joint 28 with the first and second vertical mullions 80 and 82 is shown in greater detail in
As the pressure plates 48 are fixed to the vertical mullions 26 (see
The pressure plate expansion unit 54 is shown in isolation in
The pressure plate expansion unit 54 may have an outer contour 108 that at least generally corresponds to or matches the outer contour of the pressure plates 48 and the gaskets 50. For instance, the pressure plate expansion unit 54 may have a narrow central region 110 flanked by thicker regions 112 that compliment or match the shape of the pressure plates 48 when assembled with the gaskets 50. The dimensions of the pressure plate expansion unit 54 may vary depending on a number of considerations such as its material construction, the dimensions of the pressure plates 48 and the gaskets 50, and/or the floor structure deflection limits. The pressure plate expansion unit 54 may have a height (h5) (see
Although the expansion joint 28 and the pressure plate expansion unit 54 of the present disclosure are shown applied to a zone drained curtain wall for consistency and simplicity, the expansion pieces may also be applied to mullion drained curtain walls as those with ordinary skill in the art will appreciate. In addition, it will be understood that the expansion joint 28 and the pressure plate expansion unit 54 may be applied to stick type curtain walls, unitized curtain walls, or other types of curtain walls. Furthermore, the expansion joint 28 and the pressure plate expansion unit 54 may assist in accommodating any type of force or movement/deflection that the vertical members 22 of the curtain wall experience, not only floor structure movement. The scope of the present disclosure encompasses variations such as these.
In general, the teachings of the present disclosure may find applicability in many industries including building construction industries. More specifically, the teachings of the present disclosure may be applicable to industries providing curtain walls in which the vertical members of the curtain wall are required to have a freedom of motion sufficient to accommodate building floor structure movement or other forces acting on the curtain wall.
The first vertical mullion 80 may be slid over the first outer sleeve 84 with the first outer sleeve 84 being received in the hollow slot 36 of the first vertical mullion 80 (block 126 and
The expansion joint and the pressure plate expansion unit disclosed herein permit movement of the vertical members of a curtain wall in response to deflection of the floor structures or other forces acting on the vertical members (e.g., wind, seismic forces, other building movements, etc.). The expansion joint and the pressure plate expansion unit are fabricated from compressible elastomeric materials, such as closed cell EPDM rubbers, that compress to a degree that allows greater movement of the vertical members than existing expansion joints. Applicants have found that the expansion joint disclosed herein, when assembled between the vertical mullions of a curtain wall, may accommodate up to ±15 millimeters of movement of building floor structures. The pressure plate expansion unit assists in accommodating such movement. As such, the present disclosure provides curtain walls compatible with some newer building designs having higher floor structure deflection limits.
Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.
As used herein, the phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase “at least one of” allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.
Although various example embodiments have been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. For that reason, the following claims should be studied to determine the scope and content of this disclosure.
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