Abstract:
A method includes substantially filling with joint sealant first and second kerfs in upper and lower ends, respectively, of a curtain wall member. A locating-and-retaining member of a latching member is embedded in the first kerf&#39;s sealant. A receiving-and-retaining member of a first bracket is embedded in the second kerf&#39;s sealant, the wall member initially extending upwardly and angularly outwardly relative to the first bracket. The wall member is pivoted inwardly such that an end of a nominally horizontally-disposed portion of the latching member slides along a lower surface of a supporting member of a second bracket causing the latching member to rotate downwardly, compressing foam tape beneath the horizontally-disposed portion. The end of the latching member moves past a locking member until a latch comes into latching engagement with the locking member, the foam tape decompressing and maintaining the latching member in engagement with the lower surface.

Description:
CLAIM OF PRIORITY 
       [0001]    This application is a continuation under 35 U.S.C. §120 of and claims priority to U.S. patent application Ser. No. 12/124,647 filed May 21, 2008, which will issue as U.S. Pat. No. 8,051,623 on Nov. 8, 2011, the entire contents of which are incorporated herein by reference, which is a continuation-in-part of U.S. patent application Ser. No. 11/074,086, filed Mar. 7, 2005, now abandoned, the entire contents of which are incorporated herein by reference, which claims priority of U.S. Provisional Patent Application No. 60/565,445, filed Apr. 26, 2004, now expired, the entire contents of which are incorporated herein by reference. 
     
    
     DESCRIPTION OF THE DRAWINGS 
       [0002]      FIG. 1  is an environmental view illustrating a curtain wall system installed in accordance with a first embodiment of the present invention; 
         [0003]      FIG. 2  is an illustration of a curtain wall constructed in accordance with the first embodiment of the present invention; 
         [0004]      FIG. 3  is an illustration of the curtain wall installation method in accordance with the first embodiment of the present invention; 
         [0005]      FIG. 4  is a perspective view illustrating an initial step in the utilization of the curtain wall installation method comprising the first embodiment of the first embodiment of the present invention; 
         [0006]      FIG. 5  is a perspective view illustrating a later step in the utilization of the curtain wall installation method comprising the first embodiment of the present invention; 
         [0007]      FIG. 6  is a perspective view illustrating a somewhat later step in the utilization of the curtain wall installation method comprising the first embodiment of the present invention; 
         [0008]      FIG. 7  is a perspective view illustrating a still later step in the utilization of the curtain wall installation method comprising the first embodiment of the present invention; 
         [0009]      FIG. 8  is a perspective view illustrating an even later step in the utilization of the curtain wall installation method comprising the first embodiment of the present invention; 
         [0010]      FIG. 9  is a sectional view illustrating a second embodiment of the present invention; 
         [0011]      FIG. 10  is an enlargement of the upper portion of  FIG. 9 ; 
         [0012]      FIG. 11  is an enlargement of the intermediate portion of  FIG. 9 ; 
         [0013]      FIG. 12  is an enlargement of the lower portion of  FIG. 9 ; 
         [0014]      FIG. 13  is a perspective view illustrating a third embodiment of the present invention; 
         [0015]      FIG. 14  is a side view further illustrating the third embodiment of the present invention; and 
         [0016]      FIG. 15  is an enlargement of a portion of  FIG. 14 . 
     
    
     DETAILED DESCRIPTION 
       [0017]    Referring to  FIGS. 1 and 2 , there is shown a curtain wall  10  incorporating a first embodiment of the present invention. The curtain wall  10  is supported on a wall  12 , which may be comprised of one or more layers of plywood  14 . The wall may also comprise steel studs, concrete masonry units (CMOs), concrete, etc. Other construction techniques may be utilized in the fabrication of the wall  12  depending upon the requirements of particular applications of the present invention. The wall  12  may comprise an exterior wall of a building or other structure. In such instances the wall  12  may be provided with a weather proof exterior layer  16  which is fabricated in accordance with conventional techniques. 
         [0018]    In accordance with the present invention a plurality of channels  18  are secured to the wall  12  by suitable fasteners  20 . The channels  18  may be fabricated from aluminum; however, other materials may be utilized in the fabrication of the channels  18  depending upon the requirements of particular applications of the present invention. A plurality of channels  18  may be positioned adjacent to one another to define a curtain wall support structure which extends substantially the entire width of the wall  12 . Alternatively, the channels  18  may be positioned at spaced-apart locations along the width of the wall  12 . 
         [0019]    Each channel  18  includes a curtain wall supporting member  22 , which extends perpendicularly outwardly from the wall  12 . A curtain wall receiving and retaining member  24  is located at the distal end of the curtain wall support member  22  and extends perpendicularly upwardly therefrom. The channel  18  is further provided with a locking member  26  and a stop  28 . 
         [0020]    A plurality of curtain wall members  30  are formed from limestone or other materials. For example, the curtain wall members may be formed from granite, marble, terrazzo, etc. Each curtain wall member  30  has a kerf  32  formed in the lower end thereof and a kerf  34  formed in the upper end thereof. 
         [0021]    Following installation, each curtain wall member  30  is supported by the supporting member  22  of the associated channel  18 , which is in turn secured to the wall  12  by the fasteners  20 . The receiving and retaining member  24  of the channel  18  is received in the kerf  32  of the curtain wall member  30 , which is supported on the channel  18 . In this manner the curtain wall member  30  is located and positioned relative to the wall  12  by the channel  18 . A bed of silicone  33  surrounds and flexibly retains the receiving and retaining members  24 . 
         [0022]    In accordance with the present invention, latching members  36  are utilized in conjunction with the channel  18 . Each latching member  36  includes a horizontally disposed portion  38  which ultimately extends parallel to the supporting member  22  of the channel  18 . Knobs  40  formed on the horizontally disposed portion  38  of the latching member  36  maintain proper alignment between the horizontally disposed portion  38  and the supporting member  22 . 
         [0023]    The horizontally disposed portion  38  of the latching member  36  extends to an arrow-shaped latch  42  positioned for latching engagement with the locking member  26  of the channel  18 . The distal end of the latch  42  is positioned closely adjacent to and in alignment with the stop  28  of the channel  18 . 
         [0024]    A locating and retaining member  44  is located at the opposite end of the horizontally disposed portion  38  of the latching member  36  and extends perpendicularly with respect thereto. The locating and retaining member  44  is received in the kerf  34  situated at the upper end of the corresponding curtain wall member  30  and is retained therein by a quantity of silicone  45  previously received therein. Once two adjoining wall members  30  are secured in place, an open cell backer rod  43  is inserted. Then joint sealant  46  is applied between the wall members  30  to seal against moisture penetration, to provide additional strength and stability to the wall members, and to provide a cushion allowing some movement by the wall members  30  due to wind load, foundation settlement, earthquakes, hurricanes, and the like. 
         [0025]    A method of curtain wall installation comprising a first embodiment of the present invention is illustrated in  FIG. 3 . An upper curtain wall member  30  is first supported on a channel  18  constructed in accordance with the present invention with the receiving and retaining member  24  received in the kerf  32  thereof and with the upper curtain wall member supported on the curtain wall supporting member  22 . The latching member  36  is engaged with a lower curtain wall member  30  by positioning the locating and retaining member  44  thereof in the kerf  34  of the lower curtain wall member  30 . The locating and retaining member  44  is flexibly retained in the kerf  44  by the quantity of silicone  45 . 
         [0026]    The lower curtain wall member  30  is then rotated inwardly toward the channel  18  in the direction of the arrow  47 . As the lower curtain wall member  30  rotates into position the arrow-shaped latch  42  of the latching member  36  rotates downwardly and moves past the locking member  26  of the channel  18 , thereby securing the lower curtain wall member  30  in place. Further inward movement of the lower curtain wall member  30  is prevented by engagement of the distal end of the latch  32  with the stop  28  of the channel  18 . 
         [0027]    Foam tape  48  secured beneath the proximal end of the horizontally disposed member  38  compresses to allow the latching member  36  and the arrow-shaped latch  42  to rotate into the locking member  26  of the channel  18 . Once the latching member  36  is locked in place in the locking member  26 , the foam tape  48  decompresses thereby holding the latching member  36  snugly against the support member  22  until the joint sealant  48  sets to permanently hold the latching member  36  in place. 
         [0028]      FIG. 4  illustrates the preliminary step of the curtain wall installation method comprising the first embodiment of the present invention. Channels  18  are secured to the wall  12  by suitable fasteners  20  at vertically spaced intervals substantially equal to the height of each wall member  30 . At the base of the wall a bottom channel  50  is mounted to receive a lower-most wall member  30  to be mounted on the wall  12 . The bottom channel  50  is substantially similar in construction to the channel  18  but comprises only a support member  22  and a receiving and retaining member  24  on the distal end thereof. A top channel  52  is mounted to receive the uppermost wall member  30  to be mounted on the wall  12 . The top channel is similar in construction to the channel  18  but comprises only a support member  22 , a stop  28 , and a locking member  26 . 
         [0029]    Referring now to  FIGS. 5 through 7 , there is shown the next steps in the curtain wall installation method comprising the first embodiment of the present invention which prepares the wall member  30  for mounting. As best shown in  FIG. 5 , kerfs  32  and  34  are formed in the lower and upper ends of the wall member  30 . Silicone  45  is applied into the kerfs  34  as shown in  FIG. 6 , and silicone  33  is similarly applied into the kerfs  32 . As best shown in  FIG. 7 , once the silicone is applied, foam tape  48  is secured below the distal end of the horizontally disposed portion  38  of the latching member  36  after which the locating and retaining member  44  is inserted into the kerf  32  in the upper end of the wall member  30 . The locating and retaining member  36  is flexibly secured in the kerf  34  by the silicone received therein. 
         [0030]    Referring now to  FIG. 8 , the wall members  30  are installed beginning at the top of the wall  12  and proceeding downward therefrom. Once the wall member  30  is prepared, the silicone filled kerf  34  at the lower end of a wall member  30  receives the receiving and retaining member  24  of the support member  22  located near the lower end of the wall member  30 . The wall member  30  is then rotated inwardly toward the channel  18  in the direction of the arrow  47 . As the lower curtain wall member  30  rotates into position, the arrow-shaped latch  42  of the latching member  36  moves past the locking member  26  of the channel  18  thereby securing the lower curtain wall member  30  in place. Once the curtain wall members  30  are in place an open cell backer rod  43  and then silicon sealant  46  are placed between the wall members  30 . 
         [0031]    The first embodiment of the present invention is illustrated in conjunction with the construction of curtain walls wherein the wall members  30  are formed of limestone, stone, and other like materials. However, the present invention is equally applicable to constructing walls comprising tile, porcelain, wood and various other materials used for wall curtains both on interior and exterior walls. 
         [0032]    A curtain wall  60  comprising a second embodiment of the present invention is illustrated in  FIGS. 9 through 12 , inclusive. The curtain wall  60  includes various component parts which are substantially identical in construction and function to component parts of the curtain wall  10  illustrated in  FIGS. 1 through 8  and described hereinabove in conjunction therewith. Such identical component parts are identified in  FIGS. 9 through 12  with the same reference numerals utilized above in the description of the curtain wall  10 . The curtain wall  60  differs from the curtain wall  10  in that the curtain wall  60  is designed and intended for use with relatively light weight curtain wall members fabricated from materials such as travertine stone, tile, composite materials, and the like. 
         [0033]    The curtain wall  60  is supported on a wall  62  comprising a central core  64  and internal layer  66  and an external layer  68 . The wall  62  may comprise an exterior walling of a building or other structure. In such instances, the wall  62  may be provided with a weather proof exterior layer which is fabricated in accordance with conventional techniques. 
         [0034]    In accordance with the second embodiment of the present invention, a plurality of channels  18 ′ are secured to the wall  62  by suitable fasteners  20 ′. The channels  18 ′ may be fabricated from aluminum; however, other materials may be utilized in the fabrication of the channels  18 ′ depending upon the requirements of particular applications of the present invention. A plurality of channels  18 ′ may be positioned adjacent to one another to define a curtain wall support structure which extends substantially the entire width of the wall  62 . Alternatively, channels  18 ′ may be positioned at spaced apart locations along the width of the wall  62 . 
         [0035]    The channels  18 ′ comprise three different types including a plurality of upper channels  70 U, a multiplicity of intermediate channels  701 , the exact number of which depends on the height of the curtain wall  60  and a plurality of lower channels  70 L. The intermediate channel assembly  701  each includes a channel  18 ′ having a pair of curtain wall member locators  72  and  74  extending vertically upwardly from the supporting member  22 ′. The latching member  36 ′ similarly has a pair of curtain wall member locators  76  and  78  which extend downwardly from the horizontally disposed portion  38 ′ of the latching member  36 ′. The locating member  76  extends upwardly from the horizontally disposed portion  38 ′ and over the top of the curtain wall member locator  72  of the channel  18 ′ to provide a pleasing appearance at the joints between adjacent curtain wall members. 
         [0036]    The upper channels  70 U differ from the immediate channels  701  in that the curtain wall member locators  72  and  74  are omitted and the upper portion of the curtain wall member locator  76  is configured to engage the distal end of the supporting member  22 ′. The lower curtain wall channels  70 L include the curtain wall member locators  72  and  74 , but the components of the intermediate channels  701  associated with the latching members  36 ′ are omitted. 
         [0037]      FIGS. 10 ,  11  and  12  illustrate the curtain wall system  60  having curtain wall members  80  installed therein. Each of the curtain wall members  80  has a relieved portion  82  at the upper end thereof which is received within and located by the locators  76  and  78  of the latching member  36 ′. A bead of silicone  84  is positioned between each relieved portion  82  and the locator  78  to secure the curtain wall member  80  against movement relative to locators  76  and  78 . The lower end of each curtain wall member  80  is relieved at  86  and is received between the locators  72  and  74 . A bead of silicone  88  is positioned between the lower relieved portion  82  of the curtain wall member  80  and the locator  74  to prevent movement of the curtain wall member  80  relative to the locators  72  and  74 . 
         [0038]    The curtain wall members  80  of the curtain wall system  60  are installed similarly to the installation of the curtain wall members  30  of the curtain wall system  10  as illustrated in  FIG. 8  and described hereinabove and in conjunction therewith. The installation of each curtain wall member  80  begins with engagement of the lower relieved portion  86  between the locators  72  and  74  of one of the supporting members  22 ′, it being understood that the silicone bead  88  is installed before the curtain wall member  80  is engaged between the locators  72  and  74 . The relieved portion  82  at the upper end of the curtain wall member  80  receives the latching member  36 ′ thereon, it being understood that the silicone bead  78  is installed prior to the installation of the curtain wall member  80 . 
         [0039]    After the relieved portion  86  has been engaged between the locators  72  and  74 , the curtain wall member  80  is rotated inwardly toward the channel  22 ′. As the curtain wall member  80  moves into position, the arrow-shaped latch  42 ′ moves past the locking member  26 ′ of the channel  18 ′, thereby securing the curtain wall member  80  in place. Before the curtain wall member  80  is secured in place, the silicone beads  78  and  88  are installed between the relieved portions  82  and  86  of the curtain wall member and the adjacent locators  76  and  78  and  72  and  74 , respectively. 
         [0040]    A third embodiment of the present invention comprising a system for closing the joints between adjacent curtain wall members is illustrated in  FIGS. 13 through 15 , inclusive. As is well-known current systems for filling the gaps between adjacent curtain wall members comprise use of either grout or plastic materials such as silicone. Utilization of either of the existing systems can result in difficulties caused by pressure differentiations on opposite sides of curtain wall members. 
         [0041]    Referring particularly to  FIG. 13  there is shown a mechanism for filling gaps between adjacent curtain wall billing members which eliminates the foregoing and other difficulties which have long since characterized the prior art. In accordance with the third embodiment of the present invention, a gap filling member  90  formed from a suitable plastic material is provided with a plurality of vents  92  which eliminate the possibility of pressure differentiation on opposite sides of a curtain wall member. 
         [0042]    The lower end of the gap filling member  90  includes an extension  94  useful in hiding horizontal gaps which would otherwise be readily observable when gap filling members  90  are positioned one above the other. The lower end of the gap filling member  90  further includes a hook  96  useful in securing the gap filling member  90  against dislocation. The upper end of the gap filling member  90  comprises a latching member  98  which is substantially identical in construction and function to the latching members  36  and  36 ′ described hereinabove in connection with the curtain wall members  30  and  80 . 
         [0043]    Referring to  FIG. 14 , receiving and supporting members  100 , which are substantially identical in construction and function to the receiving members  22  and  22 ′ described hereinabove and in conjunction with the first and second embodiments of the present invention include a vertically extending retainer  102 . The retainer  102  receives the hook  96  of the gap filling member  90 , thereby supporting the weight of the gap filling member  90 . 
         [0044]    The gap filling member  90  is installed between adjacent curtain wall members by first engaging the hook  96  thereof with an appropriate retainer  102 . The gap filling member  90  is then rotated inwardly toward the supporting and positioning member  100  as gap filling member  90  moves into position the arrow-shaped latch at the distal end of the latching member  104  moves past the locking member of the receiving and supporting member  100  thereby securing the gap filling member  90  in place. As pointed out above, the vents  92  of the gap filling member  90  eliminate pressure differentiation on opposite sides of the curtain wall members which extend adjacent to the gap filling member  90 . 
         [0045]    Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention.