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.

Description

FIELD OF THE INVENTION

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

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.

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.

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.

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™ 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.

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.

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.

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™ 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.

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.

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.

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.

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

FIG. 1 is a front elevation view of a typical subframe grid attached to a building according to one embodiment of a dry system.

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.

FIG. 3 is a cross sectional partially exploded side view of a typical midwall joint according to one embodiment of a dry system.

FIG. 4 is a cross sectional partially exploded side view of a typical inside corner joint according to one embodiment of a dry system

FIG. 5 is a cross sectional partially exploded side view of a typical termination joint according to one embodiment of a dry system.

FIG. 6 is a cross sectional side view of a subframe member according to one embodiment of a dry system.

FIG. 7 is a cross sectional side view of a subframe attachment slide clip according to one embodiment of a dry seal system.

FIG. 8 is a cross sectional side view of a PE attachment slide clip according to one embodiment of a wet system

FIG. 9 is a cross sectional side view of a PE member according to one embodiment of dry, wet and rain screen systems.

FIG. 10 is a cross sectional side view of a lock bar member according to one embodiment of a dry system.

FIG. 11 is a cross sectional side view of a joint snap cover member according to one embodiment of a dry system.

FIG. 12 is a cross sectional side view of a subframe union sleeve member according to one embodiment of a dry system.

FIG. 13 is a top view of a twist-lock joint anchor according to one embodiment of a wet system.

FIG. 14 is a cross sectional side view of a wide lock bar member according to one embodiment of a dry system.

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.

FIG. 16 is a cross sectional side view of a typical outside corner condition according to one embodiment of a dry system.

FIG. 17 is a cross sectional partially exploded side view of a typical midwall joint according to one embodiment of a wet system.

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.

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.

FIG. 20 is a cross sectional side view of a typical midwall joint detail according to one embodiment of a rain screen system.

FIG. 21 is a cross sectional side view of a typical subframe union joint detail according to one embodiment of a dry system.

FIG. 22 is a partially exploded front elevation view of a typical subframe union joint detail according to one embodiment of a dry system.

FIG. 23 is a cross sectional side view of a typical midwall joint detail according to a second embodiment of a wet system.

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

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”.

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.

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.

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.

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%.

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.

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

FIGS. 1-7, 9-12, 16, 21 & 22 illustrate a dry system and various components and assemblies thereof.

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.

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.

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.

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.

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.

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).

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.

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.

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.

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.

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.

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™, 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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

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.

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

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.

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™. 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

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

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

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.

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.

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.

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.