Abstract:
A mullion sealing bridge and method for use in a curtain wall system. In one aspect, the bridge is placed at an intersection horizontal and vertical mullions to divert fluid along the curtain wall system. 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.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from and incorporate by reference the entirety of U.S. Provisional Application Ser. No. 60/619,661, entitled “Curtain Wall Mullion Sealing Bridge,” filed Oct. 18, 2004. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to building curtain walls and, more particularly, but not by way of limitation, to methods of and apparatus for horizontal mullion bridging and sealing for collecting and diverting fluids, such as water infiltrating into the curtain wall system outwardly therefrom. 
     2. Description of Related Art 
     The above summary statement as to the field of the present invention is not intended to represent each embodiment or every aspect of the present invention. 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 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 plurality of extruded horizontal members intersecting with vertical members. These vertical and horizontal extruded members will be referred to herein as mullions. The horizontal mullions are typically formed with structural body regions and tongue portions extending outwardly therefrom to facilitate the mounting of the panels. For this reason, an open intersection space is generally formed between the tongue portions of the horizontal mullions at the point where the vertical mullions intersect them. It typically is necessary to fill this tongue intersection space with a combination of material and sealant in order to control the collection and flow of moisture emanating from condensation, precipitation, etc. Typical remedies for removing the fluids that collect along horizontal mullions involve apparatus and systems for bridging and channeling the flow of fluid to exit portions of the curtain wall system. Such systems and apparatus often typically require intense manual labor at the job site to adequately provide the necessary seals, subassemblies and alignment of sealant and/or parts therefor relative to assembly of the curtain wall sections. One such relative part or subassembly involves a member referred to as a thermal isolator. The thermal isolator is an elongate, elastomeric member that is typically mounted along the frontal surface of a horizontal mullion. This horizontal surface typically includes a flanged region of the mullion that provides spacing for glass panels, or the like, as well as a means for mounting the thermal isolator therealong. This aspect will be discussed in more detail below. 
     Referring specifically now to the mullion intersection space, one example of a construction approach sometimes used in the industry and referenced above, is the manual application of sealant around vertical mullions at the intersection of horizontal mullions. The sealant must be manually ramped at an incline to force the collecting fluid out of the intersection and toward the exit portion along the horizontal mullion. With this technique, the quality of the ramping of the sealant is obviously 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 vast quantities of labor are required to apply sealant in the curtain wall system. Two patent applications that address these and related water diversion issues are U.S. patent application Ser. No. 10/836,081, filed Apr. 29, 2004, and U.S. patent application Ser. No. 10/833,990, filed Apr. 27, 2004, both assigned to the assignee of the present invention and incorporated herein by reference. 
     Yet another approach to the problem described above is the use of a preformed barrier plug adapted for positioning at the intersection of the horizontal and vertical mullions. A typical barrier plug may fill the space normally occupied by both the horizontal mullion tongue and the thermal isolator secured therealong. In such configurations, the thermal isolator is generally cut where it engages the barrier plug. The thickness of the barrier plug is that necessary to accommodate the spacing of the flange and the thermal isolator for flush receipt of a pressure plate outwardly thereof. The uniformity and consistency of the mounting of a pressure plate against a thermal isolator is important, and problems can occur when the thermal isolator must be cut and applied in sections. The present invention addresses these problems by providing a method and apparatus permitting a continuous length of thermal isolator material to be secured along the horizontal mullion of a curtain wall and uniformly across the junction of a vertical mullion in association therewith. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention relates to a method of and apparatus for horizontal mullion bridging, sealing and moisture diversion in a curtain wall system. The method and apparatus of the invention comprise, in one embodiment, a preformed, selectively designed moisture diversion bridge constructed with a size and frontal profile that is substantially similar to the size and frontal profile of the adjacent horizontal mullion tongues and adapted for securement at the intersection of the horizontal and vertical mullions. In one aspect, the above-described moisture diversion bridge is placed at the intersection of the vertical and horizontal mullions where the end of a first horizontal mullion tongue and spaced therefrom across the face of the vertical mullion. The moisture diversion bridge is formed to retain and divert fluid such as moisture along the horizontal mullion for subsequent discharge out of the curtain wall system through weep holes by being mounted in and sealed along the intersection of the vertical and horizontal mullions. 
     In one embodiment of the invention, the weep holes may be formed in a variety of positions along both a pressure plate and a cover plate mounted thereover. The moisture diversion bridge of the present invention may also include a size and front profile which is sufficiently similar to the size and profile of the oppositely disposed horizontal mullion tongues to which the bridge is mounted so that a conventional thermal isolator may extend uninterrupted thereacross. In this manner, a continuous strip of thermal isolator material may be maintained thereover, without cutting around a conventional barrier plug. In this particular embodiment, the horizontal mullion is thus provided with a bridging element that substantially resembles the adjacent regions of the horizontal mullion tongue to the extent that it is adapted for receiving sealing members thereagainst in an uninterrupted fashion. Such method and apparatus thus improve multiple characteristics of the curtain wall system in accordance with the principles of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete understanding of the method and apparatus of the present invention may be obtained by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings wherein: 
         FIG. 1  is an exploded, perspective view of one embodiment of the mullion sealing bridge of present invention in position for mounting in a curtain wall; 
         FIG. 2  is a perspective view of the bridge of  FIG. 1  in a mounted configuration within the curtain wall and illustrating in an exploded view the assembly of other elements of a curtain wall system; 
         FIG. 3  is a front elevational view of a partial assembly of  FIG. 2 ; 
         FIG. 4  is a perspective view of the completed assembly of  FIG. 2 ; 
         FIG. 5  is a bottom plan view of the assembly of  FIG. 4 ; 
         FIG. 6  is an enlarged, perspective view of the mullion sealing bridge of  FIG. 1 ; and 
         FIG. 7  is a perspective view of an alternative embodiment of the mullion sealing bridge of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     It has been discovered that filling and sealing voids between vertical and horizontal mullions of a curtain wall system can be both time consuming and expensive. It has also been discovered that an uninterrupted mounting of a thermal isolator across horizontal mullions and aligned members secured therewith is advantageous. An uninterrupted mounting means that single strips of material may be installed across horizontal mullions even over intersections with vertical mullions. This permits fewer human errors and more efficiency in assembly. Since reliable sealing of the intersection between the vertical and horizontal mullions is necessary for most applications in order to prevent uncontrolled water passage, the voids created by the intersection of non-planar members, such as the vertical and horizontal mullions of a curtain wall system, present a number of design issues. The previous utilization of rigid sealing members such as conventional barrier plugs with sizes and frontal profiles not adapted to accommodate the continuous mounting of a thermal isolator thereacross has thus prompted attention to this assembly aspect. The moisture diversion bridge and system of the present invention provides a more reliable, less expensive and less time consuming method and apparatus for diverting moisture out of the curtain wall while facilitating receipt of a continuous thermal isolator across the horizontal mullion region. 
     Referring now to  FIGS. 1-5 , there is shown one embodiment of a moisture diversion bridge  100  constructed in accordance with the principles of the present invention and the mounting thereof.  FIG. 1  illustrates a top perspective view of one embodiment of a moisture diversion bridge  100  constructed in accordance with the present invention. The bridge  100  is disposed in a space or void  102  defined by the intersection of vertical mullion  104  and horizontal mullion  106 . It may be seen that the frontal profile  108  of horizontal mullion  106  includes a flange section  107  formed with a recess  110  therein adapted for receipt of a thermal isolator member thereacross as will be defined in more detail below. Likewise, in accordance with the principles of the present invention, the moisture diversion bridge  100  is constructed of a size substantially similar to flange section  107  and a frontal profile  112  which is substantially similar to the frontal profile  108 . The bridge  100  also includes a slotted region  114  of similar size and shape to slotted region  110  of horizontal mullion  106 . As will be illustrated and described below, placement of the bridge  100  within the space or void  102  in alignment with mullion  106  will allow a substantially mating engagement between the bridge  100  and the contour of the vertical mullion  104  therein facilitating alignment of the frontal profile  112  relative to frontal profile  108 . Such alignment is consistent with the principles of one embodiment of the present invention that allows the uninterrupted extension of a thermal isolator thereacross. 
     Referring now to  FIG. 2 , there is shown an enlarged perspective view of the bridge  100  mounted in the void  102  and assembled contiguous both the vertical and horizontal mullions  104  and  106 , respectively. In this position conventional sealant, such as silicone, can be applied around the perimeter of the bridge  100  and against both the vertical and horizontal mullions  104  and  106  to create a sealed moisture diversion bridge thereacross. Because of the substantial similarity of frontal profiles described above, a thermal isolator  120  may be positioned for uninterrupted mounting thereacross in a manner facilitating ease and accuracy in manual application at a construction job site. It may be seen that the thermal isolator  120  will not require cutting relative to the bridge  100 , since the bridge  100  is adapted for receipt of the thermal isolator thereacross in the same manner that the adjacent horizontal mullion sections  106  are adapted for receiving the thermal isolator. 
     Still referring to  FIG. 2 , the assembly of the thermal isolator  120  across the horizontal mullions  106  and the bridge  100  disposed therebetween is further facilitated by the application of a pressure plate  122  which is mounted to the horizontal mullion by threaded members  124  that are aligned for passing through apertures  126  formed in the pressure plate  122 . The mounting of the pressure plate  122  to a horizontal mullion is well understood as is the application of a frontal cover plate  128  thereover. In the present view, cover plate  128  is positioned for receipt over and around the pressure plate  122  for the aesthetic covering thereof as well as the passage of water therefrom as will be described in more detail below. 
     Referring now to  FIG. 3 , there is shown a front elevational view of the pressure plate  122  placed against the thermal isolator  120 . Weep holes  130  are shown formed in the pressure plate  122  and disposed immediately behind and above the thermal isolator  120  disposed therebehind. A section of the thermal isolator  120  is illustrated extending outwardly from the side of pressure plate  122  for purposes of illustration. It may be seen that any water accumulating on the horizontal mullion flange  107  will be allowed to pass therefrom and/or the region of the bridge  100  through the weep holes  130 . 
     Referring now  FIG. 4 , there is shown a perspective view of the assembled configuration of the cover plate  128  against the pressure plate  122  outwardly of the horizontal mullion  106 . In this assembly, it may be seen that the various elements of the assembly are hidden from view to provide a more aesthetically pleasing configuration as is common in conventional curtain wall construction. 
     Referring now to  FIG. 5 , there is shown a bottom plan view of the assembly of  FIG. 4 . In this particular view, cover plate  128  is shown to be formed with weep holes  140  formed in the bottom region thereof. Weep holes  140  allow the passage of moisture downwardly therethrough, which moisture is collected from discharge through the weep holes  130  in pressure plate  122 . In this manner, the method of an apparatus of curtain wall mullion sealing of the present invention facilitates the discharge of water from the curtain wall in an aesthetically pleasing configuration. 
     Referring now to  FIG. 6  there is shown an enlarged perspective view of the embodiment of bridge  100  of  FIG. 1  wherein the specific construction thereof may be more readily ascertained. The bridge  100  includes a top surface  180 , a bottom surface  182 , a front surface  184 , and a back surface  186 . The opposite sides  152  and  154  of the bridge  100  are constructed with upper and lower flanges  156  and  158 , which flanges are adapted to be positioned over and under the ends of the horizontal mullion flanges  107  described above. In one embodiment of the present invention, the bridge  100  can be secured in place utilizing the friction from pressure resulting from the flanges  156  and  158  engagement of the horizontal mullions once the bridge  100  has been slid fully into place. Other securing mechanisms could be utilized such as a snapping mechanism or a threaded fastener. Moreover, the depth of the bridge  100  as shown by arrow  160  is substantially the same as the depth of the horizontal mullion flange  107  described above. In this manner the frontal profile  112  of the bridge  100  does not extend beyond the frontal profile  108  of the flange  107  of horizontal mullion  106 . This alignment allows a generally uniform surface for the uninterrupted receipt of the thermal isolator  120  thereacross. It may further be seen that the rear surface  170  of the bridge  100  is constructed with a shape that is particularly adapted for a mating engagement with the vertical mullion  104  shown in  FIGS. 1-5 . In this manner, sealant may be easily applied around the perimeter of the bridge  100  to provide complete sealing and bridging relative to both the horizontal and vertical mullions  106  and  104 , respectively. 
     Referring now to  FIG. 7  there is shown a second embodiment of the bridge  100  of  FIG. 1 , in accordance with the present invention. Bridge  200  of  FIG. 7  comprises a bridging element of substantially the same overall shape as the bridging element  100  but with less depth. The lesser depth accommodates a horizontal mullion flange (not shown) having less depth as may be necessary in certain curtain wall configurations. Likewise, a variety of sizes as well as shapes of the frontal profile of the bridges  100  and  200  may be necessary in accordance with the principles of the present invention to accommodate various profiles of horizontal mullion flanges as well as thermal isolator mounting designs. 
     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.