Abstract:
Disclosed is a moisture collection bridge and method for use in a curtain wall system. In one aspect, the moisture collection bridge is placed at an intersection of a vertical mullion and one or more horizontal members. The moisture collection bridge is formed to collect fluid in a recess and divert the fluid out of the curtain wall system through an outlet. This Abstract is provided to comply with rules requiring an Abstract that allows a searcher or other reader to quickly ascertain subject matter of the technical disclosure. This Abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This patent application claims the benefit of and priority to U.S. Provisional patent application No. 60/467,610 filed May 2, 2003. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     The present invention relates to building curtain walls and, more particularly, but not by way of limitation, to methods of and apparatus for collecting fluids, such as water, infiltrating into the curtain wall system, and diverting said fluid outwardly therefrom. 
     2. History of the Related Art 
     The advantages of building curtain wall technology are well known and accepted in the industry. Curtain walls are typically constructed of extruded aluminum frame support members having generally U-shaped channels (although other shapes may apply) for supporting a plurality of panel members that serve as the exterior of a building. Such panel members are most often panes of glass, and often double pane glass sections, but other paneled building materials such as aluminum, granite, slate, or concrete are also utilized. Such panel members are often of identical size and shape. However, near doors, opening windows, or other access points into the building, panel members of different sizes and shapes may be utilized. 
     Curtain walls generally include a horizontal member intersecting with at least one vertical mullion. Moisture from condensation, precipitation, etc. may collect at this intersection. Typical remedies for removing the fluids that collect in the horizontal channels involve methods and apparatus for channeling the flow of fluid to an exterior portion of the curtain wall system. Such methods and apparatus typically require seals and alignment of sealant and/or parts therefor. 
     An example of such an approach is the manual sealing around vertical mullions at the intersection of horizontal members. The sealant is ramped at an incline to force the collecting fluid out of the intersection and toward the exit portion along the horizontal member. The quality of the ramping of the sealant is dependent on the skill and care of the laborer. The operation also adds additional cost and time to the project. Furthermore, human error and inconsistency is introduced when requiring a large amount of labor to be performed when ramping the sealant in the curtain wall system. 
     Another example of such an approach is illustrated in  FIG. 1 . Horizontal members  10  and vertical mullions  20  intersect, and at this intersection a water deflector  50  may be mounted. The water deflector  50  includes a sloped upper surface  60  for directing fluid to a weep slot  70 . Legs  80  hold the water deflector  60  in place. If the water deflector  50  is not placed substantially plumb to the system, then the sloping upper surface  60  may not be effective in directing fluid out of the system. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention generally relates to a method of and apparatus for moisture collection and discharge. The method and apparatus of the present invention comprises, in one embodiment, a moisture collection bridge for diverting fluid from a curtain wall system. The bridge includes a top surface for spanning a specific portion of the curtain wall system, a recess within the top surface for collecting fluid infiltrating therein, and an outlet extending from and in flow communication with the recess, for diverting the fluid to an exterior portion of the curtain wall system. 
     In another embodiment, the present invention relates to a method of diverting fluid flowing within a curtain wall system to an exterior portion thereof. The method includes forming a top surface of a moisture collection bridge for spanning a specific portion of the curtain wall system, forming a recess of the moisture collection bridge for collecting fluid infiltrating the curtain wall system, forming an outlet of the moisture collection bridge for diverting the fluid to an exterior portion of the curtain wall system, and securing the moisture collection bridge within the curtain wall system in position for the diversion of fluid flowing therein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present invention, and for further objects and advantages thereof, reference is made to the following description taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a perspective view of a water deflector for a curtain wall system; 
         FIG. 2A-2D  are various views of a schematic representation of a moisture collection bridge in accordance with an embodiment of the present invention; 
         FIG. 3  is a perspective view of the moisture collection bridge of  FIGS. 2A-2D  installed in a curtain wall system; 
         FIG. 4  is an enlarged perspective view illustrated in  FIG. 3 ; 
         FIG. 5  is a perspective view of a moisture collection bridge in accordance with an alternate embodiment of the present invention; and 
         FIG. 6  is a side elevational view of a moisture collection bridge in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     It has been discovered that, when required, the sealing of voids between a vertical mullion and a horizontal member of a curtain wall system can be both time consuming and expensive. Since sealing of the intersection between the vertical mullion and the horizontal member is necessary for some applications in order to prevent uncontrolled water passage, the voids created by the intersection of non-planar members, such as the vertical mullion and the horizontal member of a curtain wall system, present a number of design issues. The moisture collection bridge of embodiments of the present invention provides a method and apparatus for collecting and diverting moisture out of the curtain wall system. 
     Referring to  FIGS. 2A-2D , a moisture collection bridge  100  is illustrated, having a generally semi-conical, or generally quasi-infundibular shape. These terms are used herein to generally describe the shape of the moisture collection bridge  100  shown and described. As shown in  FIG. 2A , a top view of the moisture collection bridge  100 , a top surface  102  is formed, bordered by two side edges  104 ,  106 , a rear face  108 , and a front face  110 . The two side edges  104 ,  106  form protrusions on each side of the moisture collection bridge  100 . The protrusions (side edges  104 ,  106 ) rest on an upper surface of the horizontal members of the curtain wall system (not shown). Formed on the top surface  102  of the moisture collection bridge  100  is a recess  112 . Although the recess  112  of the preferred embodiment of the present invention is formed as a funnel with a semi-circular orientation, the recess  112  may also be oriented in a variety of other shapes, such as semi-octagonal, semi-rectangular, etc. The recess  112  leads to an outlet  114  to divert the fluid captured in the recess  112  out of the curtain wall system. 
       FIG. 2B  illustrates a perspective view of the moisture collection bridge  100  of  FIG. 2A . Shown more clearly in  FIG. 2B , the rear face  108  includes a lip for abutting the vertical mullion (not shown) of the curtain wall system in order to prevent leakage behind the moisture collection bridge  100  and along a top surface of the vertical mullion. Also illustrated more clearly in  FIG. 2B , the front face  110  includes a contoured lip for fitting flush against a rear surface of a horizontal cover plate. The contours of the front face  110  may be adjusted to fit a variety of shapes of cover plates or, alternatively, the front face  110  may be planar or have fewer or more contours than those shown in the preferred embodiment. The contour of the front face  110  depends on the type of curtain wall system employed and the type of pressure plate or cover, if any, that is fastened or attached by other means to the horizontal members. 
       FIG. 2C  illustrates a front view of the moisture collection bridge  100  of the present invention. The moisture collection bridge  100  may include a locking mechanism  116  to lock the moisture collection bridge  100  in place in the curtain wall system. By locking the moisture collection bridge  100  in place, less human error may be introduced and therefore failure of the moisture collection bridge  100  may be reduced. As shown in  FIG. 2D , a side view of the moisture collection bridge  100 , the recess  112  may be oriented at a grade of about 45° from horizontal. The angle of the recess  112  may be adjusted to fit the needs of the curtain wall system. 
     Referring now to  FIG. 3 , the moisture collection bridge  100  is shown placed in a curtain wall system  200 . As previously described, the two side edges  104 ,  106  extend over a portion of the horizontal members  202 ,  204  of the curtain wall system  200 . The rear face  108  abuts the vertical mullion  206  to prevent moisture from leaking behind the moisture collection bridge  100 . Sealant may be applied on a top surface and a bottom surface of the side edges  104 ,  106  and a front surface and a back surface of the rear face  108  to form a water tight seal along the top surface  102  of the moisture collection bridge  100 . The outlet  114  extends downward between and in front of two panels  208 ,  210  that may be formed of glass, marble, or other building material. The fluid is collected at the recess  112  and diverted through the outlet  114  to the exterior of the curtain wall system  200  between and in front of the two panels  208 ,  210 . In this manner, fluid is prevented from collecting in the curtain wall system  200 . Protrusions  118 ,  120  of the front face  110  are formed to abut a portion of the panels  208 ,  210  and sealed to prevent leakage between the moisture collection bridge  100  and the panels  208 ,  210 . 
     As shown more clearly in  FIG. 4 , the protrusions  118 ,  120  of the front face  110  extend along a portion of the panels  208 ,  210  and are shaped in a stepped manner to facilitate a seal between the horizontal members  202 ,  204 , the panels  208 ,  210 , and the moisture collection bridge  100 . Sealant may be applied along all edges, or a portion thereof, to create a water tight seal and prevent leakage to other portions of the curtain wall system  200 . 
     Referring now to  FIG. 5 , a moisture collection bridge  500  in accordance with an alternate embodiment of the present invention is illustrated. The moisture collection bridge  500  includes a modified rear face  508  to accommodate various protrusions of the vertical mullion  206 . A top surface  502  includes side edges  506  for abutting the horizontal members  202 ,  204 . Instead of contouring a front face  510  of the moisture collection bridge  500  as shown in the previous embodiments, the front face  510  may be substantially planar. Fluid collected by a funnel  512  is directed out of the system by the outlet  514 . Side walls of the outlet  514  also act as a stop or termination location for a lower exterior face seal gasket  520 . 
     Referring now to  FIG. 6 , a side elevational view of a moisture collection bridge  600  is shown as installed in a curtain wall system. The moisture collection bridge  600  is placed at the intersection of the vertical mullions  602  and horizontal members (not shown). The moisture collection bridge  600  may directly abut at least a portion of a cover plate  604 . In addition, side walls of the moisture collection bridge  600  may directly abut at least a portion of the lower exterior seal gasket  520 . The side walls prevent the lower exterior seal gasket  520  from blocking the outlet and reducing the effectiveness of the moisture collection bridge  600 . 
     Although the moisture collection bridge  100 ,  500 ,  600  is shown as including a funnel-shaped recess  112  and a contoured front face  110 , various other geometries and orientations are possible. In addition, the preferred embodiment is utilized at the intersection of the vertical mullion  206  and horizontal members  202 ,  204 . However, other embodiments may be formed in a similar manner to be placed throughout the curtain wall system  200  along the horizontal members  202 ,  204  or vertical mullions  206  at a variety of positions. 
     It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. While the method and apparatus shown or described have been characterized as being preferred it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the invention.