BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of a sunshade according to the present invention mounted to a curtain wall.
FIG. 2 is a partially exploded, perspective view of the sunshade.
FIG. 3 is an exploded front view of the sunshade.
FIG. 4 is a perspective view of a portion of an outrigger and a spacer of the sunshade.
FIG. 5 is a front view of the spacer of FIG. 4.
FIG. 6 is a perspective view of the sunshade during a process of being mounted to an anchor clip.
FIG. 7 is another perspective view of the sunshade during a process of being mounted to an anchor clip.
FIG. 8 is an exploded perspective view of a connector prior to installation and engagement with adjacent sunshades.
FIG. 9 is a perspective view of an end bay outrigger being installed on the sunshade.
FIGS. 10 and 11 shows an end cap usable with the sunshade.
FIG. 12 is a partially exploded, perspective view of a portion of another sunshade according to the present invention.
FIG. 13 is a perspective view of a spacer of FIG. 12.
FIG. 14 is a perspective view of a pressure plate according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
One example of a sunshade 10 according to the present invention is shown in FIGS. 1-3. The sunshade 10 is shown in FIG. 1 as partially installed on a curtain wall 12 of a building structure. The sunshade 10 reduces the amount of sunlight reaching the building structure by inhibiting passage of sunlight through the sunshade 10. A portion of a second sunshade 10 is also shown in FIG. 1 on the curtain wall 12 of the building structure. A plurality of sunshades 10, such as the two sunshades 10, 10 of FIG. 1, form a sunshade array. Each sunshade 10 is securely fastened in a cantilevered manner to the curtain wall 12 with sufficient strength to overcome at least combined wind loads, dead loads and snow loads applied to the sunshade 10. Referring also to FIG. 2, each sunshade 10 has a building mounting side 14 which is mounted to the curtain wall 12 of the building structure and a cantilever side 16 opposite the building mounting side 14. First and second opposite ends 18, 20 of each sunshade 10 extend between the building mounting side 14 and the cantilever side 16 of the sunshade 10.
Referring to FIG. 1, the sunshade 10, which is typically orientated horizontally on the building, is attached to two sunshade anchors 22 which are mounted to two spaced-apart vertical mullions 24. A mullion cover 25 is removed from the left vertical mullion 24 to show the sunshade anchor 22. The right vertical mullion 24 is shown with the mullion cover 25 in place which hides the right sunshade anchor 22 from view. The sunshade anchors 22 are the thermally broken sunshade anchors described in detail in the copending parent application. However, the present invention can be practiced using other sunshade anchors as well. FIG. 1 shows an outrigger 26 of the sunshade 10 mounted to the left sunshade anchor 22. The outrigger 26 is attached to arms 28, 30 of the sunshade anchor 22 by fasteners. Only one fastener 32 is shown in FIG. 1 as holding the outrigger 26 on the left sunshade anchor 22. When another sunshade 10 is installed, then three fasteners will be installed and tightened to mount adjacent outriggers to the left sunshade anchor 22. The right outrigger 34 of the sunshade 10 is similarly attached to the right sunshade anchor 22 (covered by the mullion cover 25).
A spacer 36 is also shown in FIG. 1 on the left outrigger 26. Prior to installation of the next sunshade 10, the spacer 36 will be moved into its installation position between the arms 28, 30 of the sunshade anchor 22 and between the adjacent outriggers. The spacer 36 is further described below.
As shown in FIG. 1, the left vertical mullion 24 of the curtain wall 12 has a notched pressure plate 38 and pressure plates 40 mounted to an interior mullion member 42 on opposite sides of glass panels 44. The right vertical mullion 24 also has a notched pressure plate 38 and pressure plates 40 which are covered by the mullion cover 25. The notched pressure plates 38 and the pressure plates 40 are components of the curtain wall 12 that capture the glass panels 44, i.e., an external glass capture member. Gaskets are provided between the notched pressure plates 38 and the glass panels 44, and between the pressure plates 40 and the glass panels 44. Gaskets are also provided between the glass panels 44 and the interior mullion members 42. Fasteners 46 securely mount the notched pressure plates 38, the pressure plates 40, the glass panels 44, the gaskets, and the interior mullion members 42 together. Horizontal mullions 48 are constructed similar to the vertical mullions 24. The curtain wall 12 includes the vertical mullions 24, the horizontal mullions 48, the glass panels 44, and the gaskets. The vertical mullions 24 include the interior mullion member 42 and the exterior pressure plates 38, 40. The horizontal mullions 48 include an interior mullion member 50 and an exterior pressure plate 52. However, the present invention can be practiced with other curtain walls having structures different than the curtain wall 12. For example, the present invention can be practiced with other curtain walls that have glass capture members that are different than the pressure plates 38, 40, 52. The present invention can also be practice with other building framing systems and other structural supports. The notched pressure plate 38 is also further described below.
Referring to FIGS. 1-3, the sunshade 10 has the left and right (first and second) outriggers 26, 34, which are spaced apart from each other, and a light passage inhibiting member 54 extending from the first outrigger 26 to the second outrigger 34. The light passage inhibiting member 54 reduces or blocks the amount of light that would otherwise reach the building structure. One example of the light passage inhibiting member 54 is a plurality of louvers. The louvers 54 can be mounted to the first and second outriggers 26, 34 by fasteners 56 or other suitable attachment methods. The louvers 54 are made of extruded aluminum, although the louvers and/or the light passage inhibiting member 54 can be made using other materials as desired.
The sunshade 10 can also have a fascia 58, if desired. The fascia 58 is attached to the left and right outriggers 26, 34 at the cantilever side 16 of the sunshade 10. The fascia 58 is made of extruded aluminum, although the fascia can be made using other materials as desired.
The first (left) outrigger 26 has an elongated body 60, an upper leg 62 extending from an upper portion of the elongated body 60, and a lower leg 64 extending from a lower portion of the elongated body 60. The upper and lower legs 62, 64 extend along substantially the entire longitudinal length of the elongated body 60. However, either one or both of the upper and lowers legs 62, 64 could extend along only a portion of the longitudinal length of the elongated body 60 or intermittently along the longitudinal length of the elongated body 60. Referring to FIG. 3, the upper and lower legs 62, 64 extend from the elongated body 60 in a direction away from the louvers 54 or the light passage inhibiting member. The upper leg 62 extends at about a right angle from an outer end of the upper portion, and, similarly, the lower leg 64 extends at about a right angle from an outer end of the lower portion.
Referring to FIG. 3, the first outrigger 26 also has a first recess 66 located proximate the upper leg 62 and a second recess 68 located proximate the lower leg 64. The first and second recesses 66, 68 extend in a longitudinal direction of the outrigger 26. The first and second recesses 66, 68 may extend along substantially the entire length of the first outrigger 26 or only a portion of the first outrigger 26. The first and second recesses 66, 68 are spacer mounting recesses as will be further explained below.
Referring to FIG. 4, the first outrigger 26 has a mounting notch 70 extending inward into the first outrigger 26 from an outer edge 72 of the first outrigger 26. As shown in FIG. 4, the mounting notch 70 has an L-shape with one leg 74 of the L-shape extending generally horizontally into the outrigger 26 and the other leg 76 extending upwardly or vertically. However, the mounting notch 70 could have other shapes as desired. The mounting notch 70 allows the sunshade 10 to be hung on and supported by the sunshade anchors 22. Referring to FIGS. 1 and 2, the elongated body 60 of the first outrigger 26 has a building mounting end portion 78 which mounts to the curtain wall 12 of the building structure, and a cantilever end portion 80 opposite the building mounting end portion 78. The mounting notch 70 of the elongated body 60 is located at the building mounting end portion 78 of the elongated body 60 of the first outrigger 26.
The second (right) outrigger 34 has the same structure as the first (left) outrigger 26. Except, the upper and lower legs 62, 64 extend from the elongated body 60 of the second outrigger 34 in an opposite direction relative to the direction of the upper and lower legs 62, 64 of the first outrigger 26, as can be seen in FIG. 3. The first and second outriggers 26, 34 are made of extruded aluminum, although the first and second outriggers 26, 34 can be made using other materials as desired.
Referring to FIGS. 1, 2 and 8, the adjacent outriggers 34, 26 of adjacent sunshades 10, 10 have a structure which conceals the fasteners 56 that mount the louver blades 54 to the outriggers 34, 26. This provides improved visual features of the sunshade 10 and the sunshade array.
Referring to FIGS. 4 and 5, the sunshade 10 has a spacer 36 slidably engaged with the first outrigger 26. The spacer 36 has a body 82 and a plurality of legs 84, 86, 88, 90, 92, 94 extending from the body 82. The spacer 36 has a pair of projections 96, 98, such as the projections on the uppermost and lowermost legs 84, 94. The projections 96, 98 extend into the spacer mounting recesses 66, 68 of the first outrigger 26 when the spacer 36 is slidably engaged with the first outrigger 26. The projections 96, 98 on the spacer 36 and the spacer mounting recesses 66, 68 (FIG. 3) of the first outrigger 26 allow the spacer 36 to slide in a longitudinal direction of the first outrigger 26, and retain the spacer 36 on the first outrigger 26. The spacer 36 can be slid onto and off of the first outrigger 26 at the open ends of the first outrigger 26, i.e. the building mounting end portion 78 and the opposite cantilever end portion 80. The spacer 36 and the outrigger 26 allow the spacer 36 to be pre-assembled onto the outrigger 26 if desired. Also, the spacer 36 is easily handled and placed into its installation position (described below) by sliding the spacer 36. This helps to significantly reduce or eliminate mishandling of the spacer 36 and to ensure proper positioning of the spacer 36. The spacer 36 fills a gap or pocket between adjacent outriggers 34, 26 when the adjacent outriggers 34, 26 are mounted to a common sunshade anchor 22. The pocket between the adjacent outriggers 34, 26 is shown in FIG. 8 at the cantilevered end portions 80, 80 of the adjacent outriggers 34, 26 as pocket 100. The pocket 100 extends along the longitudinal length of the adjacent outriggers 34, 26.
An example of mounting the sunshade 10 to the curtain wall 12 of the building structure will now be described. Referring to FIG. 1, the sunshade 10 is mounted to the two sunshade anchors 22, 22 which are mounted to the vertical mullions 24, 24 of the curtain wall 12. FIG. 1 only shows one sunshade anchor 22 as the other sunshade anchor 22 is covered by the mullion cover 25. Referring to FIG. 6, the left sunshade anchor 22 is shown installed on the vertical mullion 24. A bolt (fastener) 32 is installed through the middle bolt holes of the left and right arms 28, 30 of the sunshade anchor 22 and retained on the sunshade anchor 22 by a nut (not shown). The bolt 32 will function as a hanger hook for the sunshade 10. A bolt 32 is also installed on the other (right) sunshade anchor 22 in the same manner (the right sunshade anchor 22 is covered by the vertical mullion cover 25 in FIG. 1).
Referring to FIGS. 1 and 6, the sunshade 10 is installed by being hoisted and positioned adjacent the left and right (first and second) sunshade anchors 22, 22 mounted to the curtain wall 12. As shown in FIG. 6, the mounting notch or slot 70 in the building end portion 78 of the first outrigger 26 of the sunshade 10 is aligned with the hanger hook 32 of the first sunshade anchor 22. The sunshade 10 is moved toward the first sunshade anchor 22 such that the mounting notch 70 in the end of the first outrigger 26 slidingly receives the hanger hook 32 of the first sunshade anchor 22. The leg 74 of the mounting notch 70 is slid on the hanger hook 32 in a generally horizontal direction as shown by the arrow 102 in FIG. 6. Subsequently, the leg 76 of the mounting notch 70 is slid on the hanger hook 32 in a generally downward direction. The same procedure is performed on the right-hand side of the sunshade 10 such that the second outrigger 34 is hung on the other sunshade anchor 22. With the sunshade 10 hanging on the left and right sunshade anchors 22, 22 as just described, the sunshade 10 is in a temporary installation position and the full weight of the sunshade 10 can be supported by the curtain wall 12.
Referring to FIGS. 1 and 7, the spacer 36, which is engaged with the first outrigger 26, is slid in the direction of the arrow 104 in FIG. 7 toward the first sunshade anchor 22. The spacer 36 slides along the first outrigger 26 and is retained on the first outrigger 26 due to the projections 96, 98 on the uppermost and lowermost legs 84, 94 (FIG. 5) extending into and sliding along the spacer mounting recesses 66, 68 (FIG. 3) of the first outrigger 26. A notch 106 in the spacer 36 is provided for the hanger hook (bolt) 32 installed through the middle bolt holes of the left and right arms 28, 30 of the sunshade anchor 22. The upper and lower holes 108, 110 in the spacer 36 are aligned with corresponding upper and lower holes 112, 114 in the first outrigger 26 and upper and lower holes 116, 118 in the left and right arms 28, 30 of the sunshade anchor 22. See also, FIGS. 4 and 6. The spacer 32 can be installed onto the first outrigger 26 from either end 78, 80 of the first outrigger 26 prior to hanging the first outrigger 26 on the sunshade anchor 22. Also, the spacer 36 can be installed onto the first outrigger 26 from the cantilevered end 80 of the first outrigger 26 after the first outrigger 26 is hung on the sunshade anchor 22.
If another sunshade 10 is to be installed on the curtain wall 12 adjacent to the sunshade 10 already hanging on the curtain wall 12, then the next sunshade 10 is hung on the curtain wall 12 in the same manner as the previous sunshade 10. The right side outrigger 34 of the next sunshade 10 is hung on the same sunshade anchor 22 which has the left side outrigger 26 of the previous sunshade 10.
Referring to FIG. 8, the outriggers 34, 26 of the adjacent sunshades 10, 10 hanging on the curtain wall 12 (FIG. 1) are facing each other and form the pocket 100 between the outriggers 34, 26. More specifically, and also referring to FIG. 3, the upper leg end faces 120, 120 of the upper legs 62, 62 of the two outriggers 34, 26 face each other and are adjacent each other. Similarly, the lower leg end faces 122, 122 of the lower legs 64, 64 of the two outriggers 34, 26 face each other and are adjacent each other. The pocket 100 is formed between the two outriggers 34, 26. A connector 124 is inserted into the pocket 100 and into engagement with the cantilevered ends 80, 80 of the two adjacent outriggers 34, 26 of the two adjacent sunshades 10, 10. The connector 124 has upper projections 126, 126 and lower projections 128, 128 which extend into the upper recesses 66, 66 and the lower recesses 68, 68, respectively, of the outriggers 34, 26. The adjacent sunshades 10, 10 are held together in a desired alignment by the engagement of the connector 124 with the cantilevered ends 80, 80 of the outriggers 34, 26. The connector 124 can reduce or even eliminate the need to visually align adjacent sunshades 10, 10 when the sunshades 10, 10 are finally bolted to the sunshade anchors 22, 22. The connector 124 also helps prevent the cantilevered ends 80, 80 of the adjacent sunshades 10, 10 from becoming misaligned over time, for example, due to the adjacent sunshades 10, 10 sagging relative to each other. Accordingly, the structures of the outriggers 34, 26 allow for significant improvement to the installation of the sunshades 10, 10. Adhesive, sealant or other fastening methods can also be used where desired, for example to maintain the connector 124 at a particular location in the pocket 100.
Referring to FIGS. 1 and 6-8, the adjacent outriggers 34, 26 hanging on the same hanger hook 32 are securely fastened to the sunshade anchor 22. Bolts (fasteners) are inserted through the upper and lower bolt holes 116, 116, 118, 118 of the left and right arms 28, 30 of the sunshade anchor 22, through the upper and lower bolt holes 108, 110 of the spacer 36, and through the upper and lower bolt holes 112, 112, 114, 114 of the adjacent outriggers 34, 26. (See the bolts 130 in FIG. 9.) The three fastener bolts 32, 130, 130 are tightened to nuts to securely mount the adjacent outriggers 34, 26 and the adjacent sunshades 10, 10 to the curtain wall 12. The upper and lower bolts 130, 130 can be installed at any desired time during the installation process of the sunshade array because the individual sunshades 10 hang on the hanger hooks 32 of the sunshade anchors 22. Referring to FIG. 1, the sunshade 10 on the left-hand side of the figure is in a temporary installation position because the spacer 36 has not yet been slid to its installation position and because the upper and lower bolts 130, 130 have not been installed on the left side sunshade anchor 22. The ability of the sunshade 10 to be in the temporarily installation position greatly simplifies handling of the sunshades 10 and the installation process because of increased flexibility as to when the upper and lower bolts 130, 130 are installed.
Referring to FIG. 9, if another sunshade 10 is not going to be installed on the curtain wall 12 adjacent to the sunshade 10 already hanging on the curtain wall 12, then an end bay outrigger 132 (trim piece covering the outrigger 26) can be installed adjacent the outrigger 26. The end bay outrigger 132 has a similar structure as the outrigger 34, including an elongated body 134, and upper and lower legs 62, 64 extending from upper and lower portions of the elongated body 134, respectively. A spacer 36 is provided in the pocket 100 between the outrigger 26 and the end bay outrigger 132. The spacer 36 is slid between the left and right arms 28, 30 of the sunshade anchor 22 into the installation position shown in FIG. 9, similar to the installation position of the spacer 36 when the spacer 36 is used between two adjacent outriggers 34, 26. The end bay outrigger 132 has a mounting notch 70 as in the outriggers 34, 26. The end bay outrigger 132 is installed by being positioned adjacent the left sunshade anchor 22 mounted to the curtain wall 12. The mounting notch or slot 70 in the end of the end bay outrigger 132 of the sunshade 10 is aligned with the hanger hook (bolt fastener) 32 of the first sunshade anchor 22. The end bay outrigger 132 is moved toward the first anchor 22 such that the mounting notch 70 in the end of the end bay outrigger 132 slidingly receives the hanger hook 32 of the first sunshade anchor 22. The leg 74 of the mounting notch 70 is slid on the hanger hook 32 in a generally horizontal direction as shown by the arrow 136 in FIG. 9. Subsequently, the leg 76 of the mounting notch 70 is slid on the hanger hook 32 in a generally downward direction. A connector 124 (FIG. 8) can be inserted into the pocket 100 between the outrigger 26 and the end bay outrigger 132 as with adjacent outriggers 34, 26. The connector 124 engages the outrigger 26 and the end bay outrigger 132 and holds them in proper alignment. Referring mainly to FIG. 9 and also to FIG. 6, bolts (fasteners) 130, 130 are inserted through the upper and lower bolt holes 116, 116, 118, 118 of the left and right arms 28, 30 of the sunshade anchor 22, through the upper and lower bolt holes 138, 140 of the end bay outrigger 132, through the upper and lower bolt holes 108, 110 of the spacer 36, and through the upper and lower bolt holes 112, 114 of the outrigger 26. The three fastener bolts 32, 130, 130 are tightened to nuts to securely mount the adjacent outrigger 26 and end bay outrigger 132 and the sunshade 10 to the curtain wall 12 (FIG. 1). Referring to FIGS. 1, 2, 3 and 9, the same procedure is performed on the right-hand side end 20 of the sunshade 10 such that another end bay outrigger 132 is hung on the other sunshade anchor 22. The same spacer 36 can be used on the right-hand side end 20 of the sunshade 10 by being inserted into spacer sliding recesses 66, 68 in the right-hand end bay outrigger 132. Alternatively, another spacer, similar to the spacer 36, except that the uppermost and lowermost legs 84, 94 extend in the opposite direction can be used. The alternative spacer can be slidingly engaged on the right-hand outrigger 34 in the recesses 66, 68.
Referring to FIGS. 2 and 9, the end bay outrigger 132 has a structure which cooperates with the outrigger 26 to conceal the fasteners 56 that mount the louver blades 54 to the outrigger 26. This provides improved visual features of the sunshade 10 and the sunshade array.
Referring to FIGS. 1, 3, 10 and 11, an end cap 142 can be inserted into the pocket 100 between adjacent outriggers 34, 26. The end cap has a face portion 144 and a pair of legs 146, 146 extending from the face portion 144. The pair of legs 146, 146 are inserted into the recesses 66, 66, 68, 68 of the adjacent outriggers 34, 26. Adhesive, sealant or other fastening methods can also be used where desired, for example to maintain the end cap 142 in the pocket 100. An end cap 142 can similarly be inserted in the pocket 100 between an outrigger 26 and an end bay outrigger 132.
Referring to FIGS. 12 and 13, a portion of another sunshade 200 according to the present invention is shown. The sunshade 200 is similar to the sunshade 10 described above, except the outriggers have a different shape. The outrigger 202 has a rounded cantilever end 204 instead of a square corner shape cantilever end 80 of the outriggers 26, 34 (see FIG. 2). The end bay outrigger 206 also has a rounded cantilever end 208 instead of a square corner shape cantilever end. A medallion spacer 210 is provided at the cantilever ends 204, 208. The medallion spacer 210 has a notch 212 for the fasteners 56 so that the medallion spacer 210 can lie flat against the outrigger 202. A medallion 214 having a threaded fastener 216 can be used to secure the cantilever ends 204, 208 of the outrigger 202 and the end bay outrigger 206 together. The threaded fastener 216 of the medallion 214 extends through holes 218, 220 and is engaged with a threaded hole 222 in the outrigger 202. The sunshade 200 of FIGS. 12 and 13 is an alternative sunshade having a different decorative visual look. The present invention can also be practiced using outriggers having other shapes, for example, wedge shaped outriggers, outriggers which are curved along at least a portion of their longitudinal length, and square corner outriggers, such as the square corner outriggers 26, 34.
Referring to FIGS. 1 and 14, a notched pressure plate 38 according to the present invention is shown. As shown in FIG. 1, the notched pressure plate 38 is an exterior mullion component which is mounted to the interior mullion member 42 of the vertical mullion 24 by fasteners 46. Referring also to FIG. 14, the notched pressure plate 38 has an elongated body portion 148 and a pair of legs 150, 150 extending from the body portion 148. The notched pressure plate 38 has a notch 152 through the body portion 148 which receives the sunshade anchor 22 and allows the sunshade anchor 22 to be mounted to the interior mullion member 42. One feature of the notched pressure plate 38 is that the notched pressure plate 38 has a relatively short, predetermined length from a top end 154 to a bottom end 156. In a particular embodiment, the predetermined, short length of the notched pressure plate 38 is about 3 feet, for example.
Referring to FIG. 1, the notched pressure plate 38 is installed such that the notch 152 is located at a desired position for the sunshade anchor 22 and the sunshade 10. The top end 154 of the notched pressure plate 38 extends only a short distance (about 1½ feet) above the sunshade anchor location and the bottom end 156 of the notched pressure plate 38 extends only a short distance (about 1½ feet) below the sunshade anchor location. In an embodiment, the notched pressure plate 38 extends along the vertical mullion 24 only a sufficient distance for mounting a single sunshade array and does not extend along the vertical mullion 24 to mount two sunshade arrays. The pressure plates 40 (FIG. 1) are provided above and below the notched pressure plate 38 and extend along the remainder of the length of the vertical mullion 24. The pressure plates 40 do not need to have a notch 152 because the pressure plates 40 are not used for mounting a sunshade anchor 22 or a sunshade 10. However, if a notch 152 or other notch is provided in the pressure plates 40, the notch can simply not be used for a sunshade anchor 22.
One advantage of the notched pressure plate 38 is that the processes of installing the notched pressure plate 38, the pressure plates 40 and sunshades 10 are simplified. The notched pressure plate 38 is easily installed such that the notch 152 for the sunshade anchor 22 is located at a desired location because of the short length of the notched pressure plate 38. Also, the notch 152 for the sunshade anchor 22 can be pre-machined in the notched pressure plate 38 without concern for precisely determining a notch location on an otherwise long pressure plate, for example in excess of 20 feet. After the notched pressure plate 38 is installed, the pressure plates 40 are easily cut to a proper length and then installed adjacent to the notched pressure plate 38, i.e. above and below the notched pressure plate 38. This greatly simplifies the processes of installing pressure plates and sunshades. Also, the risks of error and waste during installation of sunshades can be reduced.
Various components of the sunshades of the present invention can be made from the same extruded aluminum alloy. For example, the outriggers, louvers, end bay outriggers, fascias, end caps and other trim pieces can all be made by extrusion from the same alloy. Accordingly, the sunshades can be anodized to have a consistent visual effect. Also, the overall cost of the sunshade may be reduced because of simplified anodized finishing. The present invention is not limited to anodized finishing and can be practiced with any other suitable finish, for example paint and mill finish. Also, the present invention can be practiced using materials other than extruded aluminum.
It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.
Patent Application
20080073036
