Curtain wall with a wall element with a frame with a compartment for a wing or the like and method for replacing an infill element in a curtain wall

A curtain wall constructed from prefabricated connecting wall elements including a frame of assembled profiles on the inside of the curtain wall and of one or more filling elements on the outside. The curtain wall contains a wall element with a two-part frame including two subframes, respectively a fixed frame part and a second frame part fitted with an infill element, where the fixed frame part is located behind the second frame part seen from the outside of the curtain wall, where the fixed frame part is equipped with a rebate into which the second frame part fits and where the relevant filling element is attached to the outside of the curtain wall on the outward looking side of the second frame part using structural silicone in such a way that this outside of the second frame part is entirely covered by the filling element.

The present invention relates to a modular curtain wall or so-called unitized curtain wall.

It is well-known that unitized curtain walls are commonly constructed in a modular fashion using rectangular prefabricated wall elements which are connected to each other sideways with seals in horizontal rows placed one above the other.

The invention more particularly relates to a type of curtain wall in the form of a so-called unitized curtain wall with wall elements consisting of a frame or so-called module of assembled aluminium profiles on the inside of the curtain wall which define one or more open compartments which must be filled with infill elements.

BACKGROUND OF THE INVENTION

In the case of a unitized curtain wall it is necessary to distinguish between, on the one hand, the structure, in other words the structural profiles of the unitized curtain wall which are assembled to form a whole, the so-called modules or frames.

It is necessary to provide a “filling” for the “openings” in the empty “compartments” in these frames, or modules, in the unitized curtain wall.

There are 3 options for the “filling” of the empty compartments, namely an infill element in the form of fixed see-through glazing, or a fixed blind panel, or a unit that opens with a door or a window.

As is the case for all windows, a window that can be opened normally consists of a fixed external frame and a wing that opens which “hangs” in the fixed external frame using window hardware.

It goes without saying that the external surface of the glazing of a fixed compartment needs to be aligned with the surface of a wing that opens.

If the fixed external frame part is “integrated” in the module of the unitized curtain wall it is still necessary to provide a wing that opens “somewhere or other” to contain the glazing of the window that opens.

By definition, such a wing has a specific flush-mounting depth and, on the other hand, needs to be fitted with window hardware placed in the rebate.

Both the vertical profiles and also the horizontal profiles of the module are such that the inside of fixed glazing rests against the rubbers placed in the appropriate grooves in these profiles.

This implies that it is impossible to flush-mount a wing without the surface of the glass protruding outside.

The profile system according to the invention is now construed so that:in the case of fixed glazing or a fixed panel, the inside rests upon the fixed inside rubbers contained in the grooves of the rubbers;the mullion has been developed in such a way that by grinding away over the entire height—and only there, not higher or lower—the required rebate with all the profiling is left allowing a wing to be flush-mounted whereby the external surface of the glazing is aligned with that of the compartments with a fixed infill element;in the case of a mullion this is necessary because there is almost automatically a fixed compartment above and below a wing and, by definition, the mullion extends over the entire height of a module;in the case of a transom this is not necessary since, by definition, a transom is found between two mullions and it is therefore easier to create a separate transom with the profiling for installation of fixed glazing on the one side and the required rebate for the installation of the wing profile on the other.

In all the other existing systems in which a wing that opens can be flush-mounted, it is also necessary in the case of fixed glazing—and also in the case of the wings that open—to make a separate additional frame containing the fixed glazing, whose frame is then permanently attached to the module in some way or other, usually with screws, in which case without the window hardware as in the case of a wing. There is no other way, as indeed the vertical mullion continues over the entire height of the module.

Existing technologies have 2 great disadvantages:for each compartment in the wall consisting of frames with entire units that open, be these fixed or ones that open, it is necessary for a separate frame to be produced to contain the glazing, fixed or mounted on the module of the wall using hardware. This takes time and time is money, however not only time, but also material;bearing in mind that the number of parts that open in a wall are just a fraction of all wall compartments, it is clear that our solution represents a very significant saving since all fixed panels and all fixed glazing can be placed directly, in other words without separate glass frames, against the structure of the module.

The heart of the invention is that with the invention a part of the vertical mullion is removed by grinding, and only for a wing compartment, rather than producing a separate frame for all compartments and then mounting them against the module.

The system according to the invention therefore features:once again, no separate external frame for a window that opens;this so-called “external frame” is created by the profiles of the frame itself, whereby the mullions across the height of the wing are removed locally by grinding, thus creating the rebate;the horizontal and vertical profiles of the external frame are designed to operate in the best possible way, whereby no account is taken of how and in what way to carry out the connection of a horizontal with a vertical profile in a perfectly windproof and watertight manner, however;accomplishing the required wind and waterproof connection by using a specially-designed plastic instrument placed on the inside of a perpendicular corner piece, and which is therefore visible when the wing is opened, which causes no problem, and in doing so achieving a perfectly sealed connection without the use of any silicone or such material and whereby this connection is such that in the event of any distortion in the rectangular window opening, under whatever influence or for whatever reason, this connection will still always remain perfectly sealed due to the fact that it is not a rigid connection, but instead achieved using a semi-supple corner piece;this corner piece is attached in the factory and therefore under perfect quality control.

The invention is therefore more specifically intended for a curtain wall in the form of a unitized curtain wall featuring a combination of fixed infill elements and of infill elements for a wing that opens, whereby both the fixed and opening infill elements all need to be aligned.

U.S. Pat. No. 8,991,121 discloses a curtain wall with the normal classic thermally non broken unitized system in which the flush-mounting of wings that open is technically impossible.

WO 99/42692 discloses the construction of a wall with frames in which a mix of fixed and opening infill elements can be applied.

However, said WO 99/42692 concerns a wall of another type than a unitized curtain wall system with structural supporting frame modules as intended in the present invention.

On the contrary, WO 99/42692 refers to a so-called “cold-warm” wall consisting of “window bands” between concrete spandrels and in which insulation is applied in line with the spandrels and for this to be achieved by mounting a small frame with the single glass panel, whereby a ventilated cavity is provided. This kind of wall system requires a fully concrete wall provided with “openings” in order to fit the see-through glazing.

In this known system, the wind and waterproof seal level with the vertical reveals of the windows is ensured by a butyl band attached to the window and the concrete or stone reveal.

Furthermore, this kind of system by definition must also be mounted from the outside—so with the use of scaffolding!

It is known, in the case of curtain walls, that the glazing can be glued to the aluminium frame with the help of structural silicone and that the glass is therefore not clamped mechanically.

An advantage of prefabricated wall elements is that they can be fabricated under ideal and controlled conditions in a factory, which is obligatory under the relevant norms and regulations when it comes to structural glazing attached with a structural silicone.

The wall elements are such that the glued glazing or other infill elements entirely or almost entirely cover the outside of the frames so that it appears from the outside as if the curtain wall is made only of glass or other infill elements whereby the frame is hidden behind the infill elements. Therefore, on the outside one only sees a glass surface or other infill elements and nothing of the structure in any material.

Such wall elements are suspended in their entirety to the basic structure of the building and connect to each other to form one continuous outer wall, whereby a wall element covers the height of one storey at minimum and typically contains two infill elements stuck one on top of the other on the frame, namely one single infill element that is non-translucent or opaque and that covers the concrete slab or structure between the floors and a see-through infill element forming a window on the relevant floor.

SUMMARY OF THE INVENTION

The present invention aims to provide a solution for at least one of the aforementioned and other disadvantages.

To this end the invention concerns a curtain wall of the modular type, constructed from prefabricated connecting wall elements assembled in rows next to each other and above each other, characterised in that the wall elements consist of a basic frame or so-called module of mullions and transoms defining one or more open compartments which are filled using a fixed infill element that is attached directly to the basic frame or using a wing with an infill element attached to a wing frame that is attached in a rebate or the basic frame, whereby the infill elements are all aligned and whereby the mullions of the basic frames are formed using one-piece profiles with an internal chamber formed by an external wall and a side wall of the mullion, whereby in the case of a compartment of a fixed infill element the infill element is attached directly to the outside wall of the mullions and whereby in the case of a compartment of a wing the rebate in the mullions is achieved by locally removing the outside wall and side wall of the internal chamber of the mullions of the basic frame level with the compartment.

Therefore, only one single structural supporting basic frame or module is required, both for the frames with fixed infill elements and for the frames with a wing that opens, but whereby, in the case of a compartment with a wing, part of the mullions is removed locally by grinding or suchlike to form a rebate, but whereby above and below the rebate the mullion profile is left intact in order to be able to fix the transoms between them.

Knowing that in any case the number of parts that open are only a fraction of all wall compartments, it is clear that the solution according to the invention represents a very significant saving since all fixed panels and all fixed glazing can be placed directly, in other words without separate glass frames, against the supporting structure of basic frames.

An advantage of such a wall element according to the invention is that this wall element cannot be visually distinguished from the other wall elements with fixed infill elements on fixed basic frames, neither from the outside nor the inside of the curtain wall.

Another advantage is that, for a wall element with a wing that opens, no separate external frame is required around the infill element, meaning that the cost of such a frame is avoided. In the case of the invention, the so-called “external frame” is achieved as it were by the profiles or the basic frame itself, whereby the mullions are ground locally at wing height to a particular depth to create the required rebate.

The lack of external frame means there is no gap to fill between this external frame and the fixed frame on which it is mounted.

The wing frame of a wing that opens or of a replacement infill element can be composed of predominantly L-shaped profiles which are attached with a first leg along the edges of the infill element to the inside of this infill element and with the second leg at a distance from these edges.

Such a wing frame is easily made to measure to fit in the rebate of the basic frame in such a way that the infill element on this wing frame is aligned with the remaining fixed infill panels in the curtain wall.

Preferably, the wall elements and the wing frames of the infill elements that open are fitted with insulation profiles all around their perimeter which are attached to the frame and which reach outside to overlap over the edges of the infill elements to which they are sealed.

The basic frames of the supporting modules preferably consist of profiles which have perpendicular ends, whereby the transom profiles with their ends extend between the mullion profiles and are connected to said profiles with screws.

This significantly simplifies the fabrication of the basic frames compared to frames with mitre connections.

In order to achieve the required wind and watertight connection between a transom and a mullion in the corners of a compartment with a wing beneficial use is made of a specially-designed plastic instrument that is placed on the inside of a perpendicular corner piece, and therefore visible in an undisruptive manner when the wing is opened. In this way, a perfectly sealed connection is created without any use of silicone or other such material and whereby this connection remains perfectly sealed even in the event of any distortion in the rectangular window frame opening, under whatever influence or for whatever reason, since it is not a rigid connection, but instead one achieved using a semi-supple corner piece.

This corner piece is applied in the factory and therefore under perfect quality control.

A wall element with a basic frame with a compartment for a fixed infill element as described above, is also well suited as the replacement of a fixed infill element in a curtain wall according to the invention, for example due to a crack or for whatever other reason.

To this end the invention relates to a method comprising the following steps:the provision of a replacement infill element on a frame in the form of an aforementioned wing frame;the supporting of the infill element to be replaced from the inside to prevent it from falling out;the loosening of the infill element to be replaced from the inside by grinding or such like around the perimeter of the infill element, the side wall and connecting wall of the side chamber of the fixed frame to which the infill element is attached, and in that way creating a rebate;the removal of the loosened infill element from the inside with the part of the fixed frame that has been ground loose;the attachment from the inside of the replacement infill element with its wing frame in the rebate;the attachment from the inside of the wing frame of the replacement infill element.

An essential aspect in this method is that the entire operation to replace a damaged infill element can be conducted entirely inside the building using a wing frame with a new infill element and therefore that no technicians or fitters are required on the outside of the building or wall.

An advantage of this method is that it can be conducted entirely indoors without creating any risks to the safety of the fitters as it takes place within the building, as opposed to curtain walls of the known type where replacing a fixed infill element is a risky undertaking carried out on the outside of the building, not to mention a costly operation, certainly in the case of a curtain wall in which an infill element must be replaced at a great height.

Another advantage is that the wing frame can be made beforehand in the protected factory environment, which is particularly important for good adhesion of the structural silicone.

Preferably, attachment of the wing frame with the replacement infill element makes use of clips, which simplifies the assembly even more.

DETAILED DESCRIPTION OF THE INVENTION

The curtain wall1shown inFIG. 1is a curtain wall of the modular type constructed from individual prefabricated rectangular wall elements2in the form of separate modules placed in rows next to and above one another to create a level wall, forming the supporting structure of the curtain wall1.

As is apparent inFIG. 2the wall elements2or modules are composed of a basic frame3of assembled one-piece profiles4on the inside5of the curtain wall1and of rectangular infill elements6on the outside7of the curtain wall1which almost entirely cover the basic frame3, whereby the basic frame3is therefore hidden behind the infill elements6so that it appears as if the outside7of the curtain wall1consists entirely of infill elements in glass or suchlike.

The wall elements2are suspended on a basic structure at floor height8, whereby a wall element2spans the height of a storey.

Preferably, the wall elements2are fitted with two infill elements, being a see-through infill element6aat floor level and preferably a non-translucent or opaque infill element6bto conceal the thickness of the floors8.

In the example in the figures the infill elements6are formed by triple glazing although this is not essential.

Frame3is constructed from one-piece mullions9and one-piece transoms10, whereby the transoms10have perpendicular ends and are connected with the mullions9using screws11.

As illustrated inFIG. 3the basic frame3contains two types of mullions9that fit inside each another telescopically, respectively a mullion9awith an open U-shaped female coupling part12and a mullion9bwith a complementary open U-shaped male coupling part13, whereby the two types of mullions9aand9bslide with their coupling parts telescopically inside each other and whereby these mullions9aand9b, with the exception of the coupling parts, are as good as symmetrical relative to a median plane14.

The mullions9aand9bof adjacent wall elements2are coupled to each other as shown inFIG. 3and thus form in their coupled state a composite rectangular beam-shaped basic profile4, as it were, consisting of two predominantly symmetrical semi-profiles9aand9bfor the mullions and10aand10bfor the transoms10.

In the example the male coupling part13is formed by two parallel legs15which grasp between parallel walls of the female part12and are sealed off using seals16and17on the free end of the legs15.

These seals are preferably formed by co-extrusion of one or two materials, respectively a rubber or suchlike and a stiff material to form a stiff foot16′ and17′ which allows the seal to be slid in the lengthways direction into the appropriate detailing during assembly of the frame3.

In the example of the figures, the basic frame3contains three transoms10, featuring a lower transom10a, an upper transom10band one or more intermediate transoms10c, in this case just one intermediate transom10c, whereby the lower transom10aand the one or more intermediate transoms10care mounted between the mullions, while the upper transom10bis mounted on the mullions9.

In terms of profiling the upper transom10aand the lower transom10bare identical to the profiles of the mullions9aand9band fit together in the same telescopic manner as shown in theFIGS. 4 and 5, whereby the lower transom10afeatures a downward facing female coupling part12and the upper transom10bfeatures an upward facing male coupling part13that, when assembled, extends into the female coupling part12of a higher wall element2. Just as the mullions9aand9b, the transoms10aand10bunite to form a composite profile4that, in terms of shape, is predominantly in line with the aforementioned basic profile4.

The intermediate transom10cdivides the frame3into two compartments3aand3band has a cross-section as illustrated inFIG. 6which in profiling terms, with the exception of the female and male coupling parts, is predominantly aligned with the composite basic profile4.

The frame structure of the curtain wall1consequently appears to be composed exclusively of identical basic profiles4, regardless of whether it is composed for the composite mullions9aand9band transoms10aand10bor for the intermediate transoms10c.

The basic profile4inFIG. 6in line with an intermediate transom10cis a rectangular tube profile with an inside wall18and an outside wall19, i.e. an inside wall18facing the inside5of the curtain wall1and an outside wall19facing the outside7of the curtain wall1against which the infill elements6are attached, whose walls18and19are connected to each other by two parallel side walls20.

The basic profile4is divided into two chambers using a partition21at a distance from the inside wall18and from the outside wall19, respectively an inside chamber22on the inside5of the curtain wall1and an outside chamber23on the outside7of the curtain wall1, whereby the outside chamber23is subdivided using two connecting walls24between the outside wall19and the partition21into three internal chambers, respectively into a middle chamber23aand two internal side chambers23bon each side of the middle chamber23a.

As shown inFIGS. 4 and 5the composite mullions9and transoms10substantially contain the same characteristics with the difference that the inside chamber22is now formed by the female and male coupling parts12and13which engage with each other and that the middle chamber23ais now open and the partition21is realised with a double wall and divided into two parts.

The internal side chambers23bare thus contained by 4 walls, namely by an outside wall19, a side wall20, a partition21and a connecting wall24.

The connecting walls24of the internal side chambers23bfeature identical yet symmetrical detailing25on the sides facing each other for the attachment of seals or other components plus a protruding part26.

Also, the outside wall19is fitted with detailing25at the level of the middle chamber23aand, at the level of each internal side chamber23b, with detailing25in the form of T-shaped recesses provided for the attachment of the infill elements6using aluminium slats27which are glued all the way around the inside of the infill elements6with structural silicone28, for example structural silicone, whereby the slats27feature a T-shaped foot29which can be slid to fit into an aforementioned T-shaped recess. The slats27need to undergo an individual check to ensure that their surface treatment will not come loose when used in structural glazing.

Also, the partition21features detailing25on the inside of the internal side chamber23bfor assembly of seals or suchlike.

The transoms10and mullions9resemble semi-profiles10aand10b, respectively9aand9b, of the basic profile4featuring the same detailing25.

Around the perimeter of the infill element6insulation profiles30and32are fitted which, as shown inFIG. 8, are attached to mullions9and transoms10of the basic frame3using hooks31which, as shown in theFIGS. 3 and 4, are clicked into place in the specially-made detailing25on the connecting walls24.

On the intermediate transom10can insulation profile32is attached as shown inFIG. 6, which connects the insulation profile32with the insulation profiles30of the mullions9.

In the corners the insulation profiles30are joined together and the insulation profiles30of the mullions10are connected with the insulation profile32of the intermediate transom10cusing L-shaped corner connectors33as shown inFIG. 8whose legs slide into the hollow insulation profiles30and32.

The insulation profiles30and32extend from the frame3to the outside7of the curtain wall1over the thickness of the edges of the infill elements6and are sealed at their outward facing free ends in relation to the infill elements6using a silicone or other sealing kit.

As shown inFIG. 5, between two rows of connecting wall elements2a horizontal seal34is attached, which extends continuously in a horizontal direction over the breadth of the curtain wall1or a part of this wall and in doing so continues over the mullions9between neighbouring connecting wall elements2, covering at least the corner connections between the mullions9and the transoms10of connecting wall elements2.

This horizontal seal34is attached during construction of the curtain wall1, as soon as a complete row of wall elements2or a part of such is constructed, on top of the row of wall elements2across the entire length of the row, after which assembly of a following row of wall elements2can begin as shown inFIG. 1by clamping the horizontal seal34on the wall elements2below with the help of the profiling34band34dwithout requiring other means of attachment such as screws or suchlike.

The horizontal seal34is a one-piece profile made of EPDM rubber or suchlike with a predominantly flat part34athat rests on top of the row of wall elements2below and continuously covers the insulation profiles30of the wall elements2across the connecting perpendicular corner connections between the mullions and transoms of connecting wall elements2and this without making cuts or extra drilling and without any silicone.

This kind of EPDM rubber seal has the advantage of being a supple seal which can, for example, be rolled onto a roll and can then simply be rolled off this roll onto the wall elements2below and clamped together with the profilings34band34con the wall elements2.

The length of the applied horizontal seals34are therefore required to be greater than the breadth J of the composite mullions9a-9bas shown inFIG. 3and is preferably such that several wall elements2, preferably all wall elements2, in a row of wall elements2can be bridged with this horizontal seal34.

Should the length of a horizontal seal34be insufficient to cover the entire length of the row below, then use shall be made of several lengths of such a seal34connecting inside the breadth of a higher wall element2where there is no danger of a leak occurring at the side of this connection and where both extremities of the horizontal seal34are stuck together or vulcanised.

The top side of the flat part34aslopes down towards the outside7of the curtain wall1to allow the good transit of water.

Preferably, the breadth K of the horizontal seal34is such that it stretches from the aforementioned most outward located leg15to or almost to the outside7of the curtain wall1, so that, when in situ, this horizontal seal34acts as a sort of sill for the drainage of rainwater towards the outside7of the curtain wall1.

Any infiltration water that might possibly infiltrate via the vertical joints will be carried away row by row via the underlying horizontal seal34towards the outside7of the curtain wall1as shown with indication L inFIG. 4. For the attachment of the horizontal seal34the flat part34aon the underside is fitted with a downward facing profiling34bwhich, as illustrated inFIG. 4, is fitted with barbs and which clamps tight into a groove contained by the walls or the double wall partition21of the underlying transom10b.

The outward facing edge of the horizontal seal34is fitted with a first detailing34dwith which the seal34can be attached to the underlying insulation profile30and with a second detailing more towards the inside5of the curtain wall1. In this way, the horizontal seal34is clamped onto an underlying wall element2in3places.

Furthermore, the horizontal seal34is made with an upstanding edge34eof a height of for example 20 mm which extends into the female coupling part12of the lowest transom10aof the wall elements2above and which clamps and seals between this female coupling part12and the upwardly extending leg15inside of the male coupling part13that is located closest to the outside7of the curtain wall1.

The upstanding edge34ekeeps out any infiltration water and is fitted at the top with a hook-shaped bent end34fthat grasps the aforementioned upstanding leg15.

At the level of the uppermost corners of connecting wall elements from an underlying row, the sideways connecting wall elements are connected together using a coupling profile35as shown inFIG. 5in order to perfectly align the connecting wall element to ensure that the infill elements6on the outside7of the curtain wall1form a single surface.

The wall elements2are sealed depth-wise along their perimeter from the outside7to the inside5of the curtain wall1on four levels A, B, C, D against each other as shown in theFIGS. 3, 4 and 9.

A first level A closest to the outside7of the curtain wall1is formed by first seals36which are attached respectively to the insulation profiles30of the mullions9and of the lowest transom10a.

The second level B is formed by second seals37which are attached to the mullions9and to the lowest transom10aof the basic frame3in a detailing25of the connecting walls24.

The first and second seals36and37on the mullions seal each other, while the first and the second seals36and37seal the lowest transom10aon the underlying horizontal seal34.

The third level C is formed by the upstanding edge34eof the horizontal seal34and by the aforementioned seals17between the female and male coupling parts12and13.

The innermost fourth level is formed by the aforementioned seals16between the female and male coupling parts12and13.

In this way a perfect water and airtight seal is achieved between the wall elements2and thanks to the continuous horizontal seal34also between the rows, whereby each row is isolated from another row in terms of water drainage and all the water from each row is transported via the horizontal seal34towards the outside7of the curtain wall1.

FIG. 10shows a curtain wall1according to the invention whereby beside the wall elements2with fixed infill elements6a wall element2is now also fitted of which the one compartment3aof the basic frame3is fitted with an outward-opening wing of a window while compartment3bfeatures a fixed infill element6a.

The wing that opens is composed of a wing frame3″ and, attached to this wing frame3″, an infill element6athat is fixed to the outside7of the wing frame3″ using structural silicone28.

In terms of dimensions, the infill panel6aof the wing is the same size as a fixed infill panel6aand covers the wing frame3″ entirely or as good as entirely and is aligned with the other infill panels6, so that no difference can be seen from the outside7of the curtain wall1between fixed infill panels6and infill panels of a wing.

When closed, the wing lies in a rebate40fitted along the perimeter of the compartment3aof the wing in the basic frame3, whereby this rebate40is formed by the fact that part of the internal chamber23bof the mullions9and transoms10is missing or has been removed.

As far as the mullions9are concerned the rebate40is formed by locally removing the mullions9in the basic frame3in line with the wing as shown inFIG. 16whereby a part of the mullions9above and below the rebate is retained.

The rebate40is formed by opening the internal side chamber23bby locally removing the side wall20of the internal side chamber23bas far as the double walled partition21, the outside wall19of the side chamber23band a part of the connecting wall24as far the protrusion26.

The outward facing sides of the remaining partition21and of the protrusion26both form a stop for the wing frame3″, and do so with the intervention of a seal38, respectively39, to which the seal38is attached in the detailing25or the partition21and the seal39is attached to the wing frame3″.

Equally the transoms10on the top and bottom side of the winged compartment3afeature an appropriate rebate40spanning their entire length.

With the fact that the rebate40stretches over the entire length, the transoms10made by profiles10aand10ccan already allow for such a rebate40during fabrication or by using profiles with an internal chamber23bwhich is opened across the entire length in the same way as for the rebates40in the mullions9.

When ground in this way the mullions, on the one hand, and transoms extruded with the rebate, on the other, of the basic frame3thus form the external frame of the window as it were, so that no separate external frame is required to make a window that opens as is the case in traditionally known curtain walls. The invention lies in the fact that by applying the grinding technique to the mullions—where required in a wall compartment3afeaturing a wing that opens—, in the adjoining compartment or in the adjoining compartments of the same wall module and featuring a fixed infill element, no additional frame is required around these fixed infill elements in order to be able to place these in the basic frame3, contrary to all existing systems.

The wing frame3″ of the wing is formed by profiles41which are predominantly L-shaped with a leg41aand a leg41b, this wing frame3″ with its outward facing side facing the outer face7of the curtain wall1with one leg41ausing an aforementioned aluminium slat27all around being glued against the inside of the infill element that opens6ausing a structural silicone28and with the other leg41bfacing in a perpendicular direction to this internal side.

The seal39and a shortened insulation profile30″ are attached to the leg41a.

The rebate40is measured with ample room for traditional hardware42, for example in the form of friction hinges.

For the intermediate transom10cwith rebate40in line with the protrusions26of the remaining connecting walls24an extra insulation slat43is attached as shown in theFIGS. 13 and 16.

In the corners of the basic frame3a sealing corner piece44made of rubber, plastic or other sealing material is fitted against the inside of the rebate40and this is shown in the cross-sections of theFIGS. 14 and 15and of which the installation is clarified using theFIGS. 16 to 18.

The corner pieces40are intended to perfectly seal the perpendicular corner connections between mullions9and transoms10. After all, wind and rain penetrating the rebate between the basic frame3and the wing frame3″ must be stopped from entering the inside5of the curtain wall1via this corner connection.

The corner piece44shown in the figures is formed and sized in such a way that it attaches level with the rebate40in the intermediate transom10cagainst the underside of the remaining connecting walls24and against the outside of the remaining protrusions26as shown inFIG. 14and inFIG. 17at the bottom.

As shown inFIG. 17certain detailing25can therefore be removed in the corners across a particular length M by grinding or suchlike in order to obtain flat surfaces against which the corner piece44can be properly attached without the corner piece44needing to be made in a complex shape.

The length M across which the detailing25is removed can be chosen in such a way that when tightening the transom10against a connecting mullion9during assembly, the corner piece44is clamped between the remaining part of the overlying detailing25of the transom10and the connecting mullion9.

As far as the corner pieces44in the corners of the intermediate transom10care concerned, the corner piece44in vertical cross-section is predominantly U-shaped with a back44aand a short leg44band a long leg44cand, on the free edge of the long leg44can outward stretching lip44dthat is perpendicular to this leg44cand which adjoins a connecting wall24of a connecting side chamber23b.

The short leg44btherefore sits tightly in an upward-reaching groove46of a connecting wall24of the intermediate transom10cof the fixed basic frame3.

In this same way, in the corners of the lowest transom10aan analogue corner piece44is attached with the short leg44bfitting into a corresponding downward-facing groove45of this transom10aon the basic frame3.

In the horizontal cross-section ofFIG. 15and inFIG. 18at the bottom it is possible to see that the corner piece44with a side edge44eof the back44aconnects against the remaining part of the connecting wall24of the rebate40.

The short leg44bis extended sideways past the edge44eof the back44aand sits sideways with this extended part44b′ contained sideways in the groove45of a mullion9.

The long leg44cis also extended sideways and uses this extended part44c′ to grip across the protrusion26of the remaining connecting wall24.

Also, the lip44dis extended with a part44d′ beyond the edge44einto the rebate40of the connecting mullion9, thus buffed up against the cut edges46which limit the rebate40in the mullions on the top and bottom.

The corner pieces44are preferably glued into the fixed basic frame3.

It is clear that a corner piece44for connection to the left-hand mullion9is the mirror image of the corner piece44of the figures for connection to the right-hand mullion9.

It is clear that the corner pieces for the lowest transom10amust vary somewhat from the corner piece44of the figures.

As the corner pieces44are made of rubber or another supple or semi-supple sealing material, these corner pieces44can cope with differential settings and the potential warping or distortion of the basic frame3without harming the water and airtight function and are able to do this without the use of any silicone or other kit material.

The corner pieces44are attached during the wall builder's production process in the factory and consequently under perfect quality control. As such, for example, the corner pieces are slid onto the ends of the transoms during production before the transoms are attached between the mullions9and are screwed tightly in-between.

When the wing is opened the corner pieces44become visible, but this causes no problem. A curtain wall1system according to the invention is particularly well-suited to the prefabrication of wall elements2, be these fixed wall elements with fixed infill elements6or wall elements with a wing that opens, on an automated production line under working conditions that can be accurately controlled, therefore guaranteeing a perfect finish.

Such a production line is shown in a diagram in theFIGS. 19A and 19Bin which use is made of a production line47.

The production of the glazed wall elements2is carried out in the ten consecutive steps a through j as shown inFIG. 19:

a/ cutting all the profiles of the mullions9and transoms10and the insulation profiles30and32to the right length;

b/ machining, and if necessary grinding, the profiles using an automated machining device to create a rebate40;

c/ positioning the profiles on the production line47with the inside of the mullions9and transoms10facing downwards in a position relative to the frame3under fabrication;

d/ sliding in the aluminium slats27to allow structural gluing of the infill elements6and the attachment of the glass supports48;

e/ assembling the frames3by placing the screws11which connect the mullions9with the transoms10and installing all rubber seals16,17,36,37,38,39and corner pieces44;

f/ placing the wing frames3″ for the wings that open and for the required hardware42in the compartments in which a wing that opens is anticipated;

h/ applying the structural silicone28;

i/ placing and securing the insulation profiles30and32for the thermal break;

j/ sealing the insulation profiles30and32along the edges of the infill elements6with the help of a silicone or other sealing kit.

It should be noted that throughout the entire production process the frames remain flat on the production line and consequently no time-consuming manipulation is required to turn the frames over, something that saves significant amounts of time.

It should also be noted that the prefabricated wall elements2are already fitted with all seals during production in a controlled environment, with the exception of the horizontal seal34which is only attached during assembly in the curtain wall1in a row of in situ wall elements2before a following row wall elements is installed.

Furthermore, the system of a curtain wall1according to the invention is highly suitable for the replacement of a fixed infill element6a, for example due to damage or a crack49in the infill element6ain a compartment3aas shown inFIG. 20or for whatever other reason.

To this end a wing frame3″ with a replacement infill element6ais fabricated beforehand as shown in theFIGS. 22 to 24, similar to the wing frame3″ inFIG. 11for a wing that opens consisting of L-shaped profiles41with the required insulation profiles30″ sealed along the edges of the infill element6aand fitted with seals36and39all around.

The L-shaped profiles41on the leg41bare fitted with a sideways elastic clip connection50aon the vertical profiles41as shown inFIG. 22and on the uppermost profile41of the wing frame3″ as shown inFIG. 24and on the lowest profile41of the wing frame3″ a reinforcement lug51awith a downwards-facing lip as shown inFIG. 23.

In order to remove the broken infill element6a, use is first made from the inside of one or several suction cups applied to the inside of the broken infill element in order to hold and manipulate the infill element from the inside. In doing so the suction cups are attached to the inside of the building making it impossible for the infill element for replacement6ato fall down.

Then the basic frame3around the broken infill element6ais sawed or ground along the lines E as shown inFIG. 21, whereby the infill element for replacement6acan be removed with a part of the basic frame3as shown with arrow O inFIG. 21and a rebate40remains in the remaining part of the basic frame3.

In the corners of the rebate40appropriate corner pieces44are applied and one or more, preferably two complementary clip connections50bare attached with screws or suchlike at the level of the mullions9and of the upper transom10cof the compartment3aof the infill element for replacement6aand one or more complementary reinforcement lugs51bon the lower transom10a, each reinforcement lug51bwith an upward-facing lip behind which the downward-facing lip of the reinforcement lug51aof the wing with the replacement infill element2can be hooked as shown inFIG. 23.

Once the broken infill element6awith the attached cut frame part of the basic frame3is removed, a seal38is then attached in the remaining detailing25on the partition21and an insulation slat43is attached in the intermediate transom10cas shown inFIG. 24.

All that then needs to be done is to attach the tailor-made prefabricated wing frame3″ with the replacement infill element6afirst from the inside in the remaining opening in the curtain wall1, using the aforementioned suction cups, by turning the wing frame3″ from the inside towards the outside and by placing it with reinforcement lugs51aon its lowest profile41on the lowest reinforcement lugs51bin the rebate40with the lip of the reinforcement lugs51ahooking behind the lip of the reinforcement lugs51b.

Once the wing frame3″ with replacement infill element is placed horizontally in the correct position, this wing frame3″ resting on the reinforcement lugs51aand51bis tipped inside with a rotating pulling movement around the rotation axis through the contact line between the lugs51aand51bas shown with arrow I inFIG. 22, and clipped tight in the curtain wall1by hooking the elastic clip connections50aand50binto each other as shown in theFIGS. 22 and 24.

The reinforcement lugs51aand51bare shaped in such a way that the wing frame3″ slides easily into the correct position in the rebate40or the basic frame3.

Throughout the entire operation the installers are inside the building.

The present invention is in no way limited to the example described and the embodiment shown in the figures of a modular curtain wall according to the invention and related20wall elements and method for the fabrication of this kind of wall element, but such curtain wall and wall element according to the invention can be realised in all kinds of forms and dimensions without departing from the scope of the invention.