Abstract:
A support anchor for fastening to a vertical mullion of a curtain wall system is disclosed. The support anchor fastens to a hollow tongue web portion of the vertical mullion. 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  
       [0001]     This application claims the benefit of, and incorporates by reference the entirety of U.S. Patent Appl. No. 60/576,017 filed Jun. 1, 2004 as well as U.S. Patent Application No. 60/638149 filed Dec. 21, 2004. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Technical Field  
         [0003]     The present invention relates in general to curtain wall systems and, more particularly, but not by way of limitation, to a curtain wall system incorporating a vertical mullion for engagement with an exterior mounting anchor configured to mate therewith in support of a structure, such as a sunshade, or the like, outwardly of the curtain wall.  
         [0004]     2. History of Related Art  
         [0005]     Curtain wall systems are well known in the building industry and generally incorporate a plurality of vertical and horizontal load bearing members designed for the support of panels which are both functional as well as aesthetically pleasing. Oftentimes the panels are glass, providing a substantially transparent finished curtain wall. Due to this transparency, it is sometimes desirable to mount shading structures above the panels. Obviously, the type of and/or weight of material disposed outwardly of any curtain wall, and supported thereby, could have a direct bearing upon the design of the curtain wall and/or the design of the curtain wall interconnection system that accommodates the outwardly mounted structures.  
         [0006]     For reference purposes, representative glass curtain wall systems illustrating various commercially-acceptable design aspects are set forth and described in U.S. Pat. No. 4,005,923 issued on Nov. 1, 1977. This system, assigned to the assignee of the present invention, is representative of certain curtain wall constructions. Likewise, U.S. Pat. No. 4,899,508, which issued on Feb. 13, 1990 and assigned to the assignee of the present invention, teaches yet another paneled curtain wall system addressing aspects of curtain wall design and construction. The utility of curtain wall assemblies is well known, and curtain walls have received wide-spread commercial acceptance.  
         [0007]     Glass panel curtain walls are very popular and are often designed and constructed with extruded aluminum members in association with steel mullions. The various components of the curtain wall system are fabricated at factories and either preassembled into subassemblies or transported to job sites where on site assembly occurs. In either case, the actual construction of the curtain wall occurs at the job site, and it is very important that consideration be given to efficiencies in construction from both safety as well as reliability standpoints. The vertical and horizontal mullions may also be constructed in predetermined shapes and lengths and assembled piece by piece into a building grid. The structural interconnection between the mullions and/or anchors extending outwardly from the mullions are, in many designs, configured for the most appropriate structural interconnection deemed appropriate by the designer and/or structural engineer.  
         [0008]     As referenced above, structures disposed outwardly of glass panel curtain wall systems include sunshades. Such devices have been installed on buildings and over windows for many years. In the main, these structures are mounted outwardly from, secured to, and supported by the structural curtain wall mullions. In particular, the vertical mullion of the curtain wall is typically used to support the mounting bracket or anchor for the external structure such as the aforementioned sunshade. The assignee of the present invention has, for many years, installed sunshade systems externally of curtain wall systems utilizing various structural interconnection members. Likewise, other building systems have incorporated such sunshade support structures. It is well known that the manufacture of curtain wall systems includes both selective design aspects that are incorporated during the manufacturing process of curtain wall sections, as well as installation applications that are provided for during the application and/or installation process.  
         [0009]     One of the most popular curtain wall designs in contemporary building is that of the generally contiguous panels members such as glass. The glass panels may be in a single or multiple pane configuration. Major considerations in the use of panel members are, of course, structural integrity, aesthetics, and the sealing to resist water infiltration and drainage of water that has infiltrated the panel members. In order to maintain such structural integrity as necessary to meet building codes, design consideration must be given to all loads upon the curtain wall system. Not the least of these loads is the portion of the curtain wall system that supports not only the panel members but any members and/or structures outwardly disposed therefrom. For example, a support member or anchor may extend from the curtain wall system for supporting sunshades and the like.  
         [0010]     To date, many designs for cantilevered anchors extending outwardly from the vertical mullions of the curtain wall system have implemented configurations that include fasteners that penetrate through a front face of the vertical mullion and into a void. As shown in U.S. Pat. No. 6,421,966, a sunshade is anchored to a vertical mullion via a plurality of fasteners that penetrate a front face of the vertical mullion and are secured through the void of the vertical mullion. The fasteners are oriented in-line with tension forces created by the sunshade. In this configuration, it may be seen that the fasteners above the support brackets will be placed in tension relative to all loads applied thereto due to the weight of the loads thereon.  
         [0011]     Another design is that set forth shown and described in co-pending U.S. Patent Application Ser. No. 60/576,017 filed on Jun. 1, 2004. In that application, there is disclosed a curtain wall system wherein a plurality of holes are provided in a web section of a vertical curtain wall system allowing a cantilever member to be supported by a plurality of fasteners extending therethrough in a manner generally perpendicular to tension forces. In yet another embodiment of that invention, the cantilevered support member is specifically configured to matingly engage the vertical mullion web extending outwardly of and incorporating a portion of the curtain wall. In accordance with yet another aspect of that invention, a system for retro-fitting curtain walls with cantilever support anchors for the support of sunshades and the like is provided wherein a series of apertures transverse from a front face of a vertical mullion may be formed facilitating the coupling with and structural security of the cantilevered support anchors. In one embodiment, the anchor itself may be pre-fabricated and a pre-selected hole pattern may be provided therewith. In this manner, a template may be afforded by pre-drilling predetermined web sections of a vertical mullion therein and assembling the anchor thereto.  
       SUMMARY OF INVENTION  
       [0012]     The present invention relates to a curtain wall system incorporating an exterior mounting anchor configured to mate with a vertical mullion of the curtain wall. More particularly, one aspect of the present invention includes a curtain wall system wherein a web section of a vertical curtain wall system is adapted to receive a cantilever member and supported by a plurality of fasteners extending transversely therethrough.  
         [0013]     In yet another embodiment, the web section includes a hollow tongue portion of the mullion and the cantilevered support member is specifically configured for insertion in, and mating engagement of, the hollow tongue portion of the vertical mullion. In that embodiment, the support member includes elongate shoulder regions extending along opposite sides thereof for abutting engagement with a face of the hollow tongue mullion.  
         [0014]     In a further embodiment, one aspect of the present invention relates to a curtain wall system wherein a plurality of holes are provided in a vertical mullion web extending outwardly of and incorporating a portion of the curtain wall allowing the cantilever member to be supported by a plurality of fasteners extending therethrough in a manner generally perpendicular to tension forces. The cantilevered support member may be specifically configured to matingly engage the web.  
         [0015]     In accordance with yet another aspect of the present invention, a system for retro-fitting curtain walls with cantilever support anchors for the support of sunshades and the like is provided wherein a series of apertures transverse from a front face of a vertical mullion may be formed facilitating the coupling with and structural security of the cantilevered support anchors.  
         [0016]     In one embodiment, the anchor itself may be pre-fabricated and a pre-selected hole pattern may be provided therewith. In this manner, a template may be afforded by pre-drilling predetermined web sections of a vertical mullion therein and assembling the anchor thereto.  
         [0017]     In yet another embodiment, the present invention relates to an anchor that is configured to matingly engage the web of the vertical mullion. The vertical mullion has a plurality of apertures for facilitating fasteners extending therethrough in a pre-selected hole pattern for structural interconnectivity therewith. In this manner, the fasteners at the anchor attachment relative to the vertical mullion web are providing support in shear rather than in tension.  
         [0018]     In yet another embodiment, the fasteners are threaded members such as bolts that provide, due to their thickness and placement relative to the anchor and vertical mullion web, sufficient structural support for the weight applied to the anchor.  
         [0019]     In yet another embodiment, as described below, trim plates may be utilized in conjunction with the anchor and vertical mullion web to cover the interconnectivity between and provide and aesthetically pleasing appearance thereto. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]     Further advantages and specific details of the present invention will become apparent hereinafter from the detailed description given below in conjunction with the following drawings.  
         [0021]      FIG. 1  is a perspective view of a support anchor and vertical mullion in accordance with an embodiment of the present invention;  
         [0022]      FIG. 2  is an assembly diagram of the support anchor and vertical mullion of  FIG. 1 ;  
         [0023]      FIG. 3  is a perspective view of the vertical mullion of  FIG. 1 ;  
         [0024]      FIG. 4  is a perspective view of an alternative embodiment of a support anchor and vertical mullion in accordance with the principles an embodiment of the present invention;  
         [0025]      FIG. 5  is an assembly diagram of the support anchor and vertical mullion of  FIG. 4 ;  
         [0026]      FIG. 6A  is a top plan, cross-sectional view of the support anchor and vertical mullion of  FIG. 4 ;  
         [0027]      FIG. 6B  is a side plan view of the support anchor and vertical mullion of  FIG. 4 ;  
         [0028]      FIG. 7A  is a top plan view of a support anchor in accordance with an embodiment of the present invention;  
         [0029]      FIG. 7B  is a side plan view of the support anchor of  FIG. 7A ;  
         [0030]      FIG. 8  is a top plan view of the support anchor and vertical mullion of  FIG. 4 ;  
         [0031]      FIG. 9  is a flow chart of one embodiment of certain methods of the present invention;  
         [0032]      FIG. 10  is a top plan view of an alternative embodiment of the present invention; and  
         [0033]      FIG. 11  is a top plan view of a further alternative embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0034]     Embodiments of the present invention provide a curtain wall system anchor adapted for supporting external cantilevered loads relative to the curtain wall system. The loads may include external structures, such as sunshades. The anchor is secured to and supported by the curtain wall system by transverse fasteners extending transversely through a hollow tongue mullion portion of the curtain wall system.  
         [0035]     Referring now to  FIG. 1 , a support anchor  200  and vertical mullion  202  in accordance with an embodiment of the present invention is illustrated. The support anchor  200  is secured to the vertical mullion  202  with fasteners  204  oriented transversely to tension placed on the support anchor  200 . The fasteners  204  secure the support anchor  200  via apertures placed in a hollow tongue, web portion  206  of the vertical mullion  202 . This aspect will be illustrated most clearly in  FIG. 3 . A face cover  208  may be oriented to cover a portion of the vertical mullion  202  and the support anchor  200 , as illustrated most clearly in  FIG. 2 .  
         [0036]     Still referring to  FIG. 1 , the support anchor  200  may be utilized to secure sunshades or various other mechanisms to a curtain wall system. The support anchor  200  may be oriented at any portion of the vertical mullion  202  and is not restricted to being fastened to the curtain wall system at an intersection of the vertical mullion and horizontal member.  
         [0037]     Referring now to  FIG. 2 , an assembly diagram of the support anchor  200  and vertical mullion  202  is shown. The support anchor  200  is attached to the hollow tongue web portion  206  of the vertical mullion  202  via fasteners  204 . The face cover  208  is attached by snapping over a pressure plate  210 . The pressure plate  210  is attached to the front face  206   a  of the web portion  206  via fasteners  211 . By attaching the support anchor  200  to the vertical mullion  202  in this manner, no penetration is made through the vertical mullion into a mullion void  202 A thereof. By not penetrating the void  202 A, additional sealing of the vertical mullion  202  is not necessary when securing the support anchor  200 .  
         [0038]     Referring still to  FIG. 2 , the face cover  208  is shown to be formed of upper and lower portions  208 A and  208 B, each having a central slot  209  formed therein. The central slot  209  in upper and lower portions  208 A and  208 B, respectively, is sized to receive the support anchor  200  extending therethrough. Likewise, the pressure plate  210  is constructed with a central slot  210 A adapted for alignment with slot  209  in receipt of the support anchor  200  therethrough.  
         [0039]     Continuing to refer to  FIG. 2 , the support anchor  200  is further constructed with a plurality of external mounting apertures  231  in an external mounting surface  233  thereof. An internal mounting surface  235  adapted for receipt within the hollow tongue web portion  206  likewise contains a series of internal mounting apertures  237 . The apertures  237  are adapted for registry with the apertures  207  of the hollow tongue mullion web portion  206  to therein receive the fasteners  204  therethrough. Likewise, the support anchor  200  is formed with an elongate shoulder region  240  which extends along both sides and the full length thereof. The shoulder region  240  is adapted for abuttingly engaging the face  206 A of the hollow tongue web portion  206  once surface  235  is mounted therein. In this manner, weight applied to the support anchor  200  through apertures  231  outwardly of the vertical mullion  202  is transferred directly to the vertical mullion  202  by the abutting engagement of the shoulder region  240  thereagainst, as well as the securement thereof through the fasteners  204 .  
         [0040]     Referring still to  FIG. 2 , the assembly diagram also illustrates a series of threaded members  205  which are adapted for receiving and securing the fasteners  204 . The threaded members  205  are shown as threaded nuts and are placed in alignment with apertures  207  formed in the hollow tongue web portion  206  of the vertical mullion  202 . A thermal isolator strip  221  is also shown in a bifurcated section above and below the support anchor  200  in position for abutting engagement therewith while being secured to the extruded mouth  223  of the hollow tongue web portion  206  of the present invention.  
         [0041]     Referring now to  FIG. 3 , there is shown an isolated perspective view of one embodiment of the vertical mullion  202  and the construction thereof. It may be seen that the hollow tongue web portion  206  is constructed with an inside wall  216  that completely seals the hollow tongue web portion  206  from the inside void  235   
         [0042]      202 A of the vertical mullion  202 . In this manner, a vertical slot  250  may be cut in the hollow tongue web portion  206  as shown for receipt of the support anchor  200  therein with the mounting apertures thereof in registry with the apertures  237  of the support anchor.  
         [0043]     Although the support anchor is illustrated as having four apertures  231  for connecting to other elements, such as sunshades, it will be understood by one skilled in the art that more or fewer than four apertures may be present in any orientation on the support anchor  200 . In addition, more or fewer fasteners  204  may be utilized to secure the support anchor  200  to the web portion  206 . The support anchor  200  may also be formed in a variety of shapes other than that shown (i.e., rectangular, square, semi-circular, etc.).  
         [0044]     Referring now to  FIG. 4 , a support anchor  100  and vertical mullion  102  in accordance with another embodiment of the present invention is illustrated. The support anchor  100  is secured to the vertical mullion  102  with fasteners  104  oriented transversely to tension placed on the support anchor  100 . The fasteners  104  secure the support anchor  100  via apertures placed in a web portion  106  of the vertical mullion  102 . A face cover  108  may be oriented to cover a portion of the vertical mullion  102  and the support anchor  100 .  
         [0045]     The support anchor  100  may be utilized to secure sunshades or various other mechanisms to a curtain wall system. The support anchor  100  may be oriented at any portion of the vertical mullion  102  and is not restricted to being fastened to the curtain wall system at an intersection of the vertical mullion and horizontal member. In addition, the support anchor  100  may be retro-fitted to existing curtain wall systems without total disassembly of the system in order to secure fasteners through the vertical mullion void (shown in greater detail in  FIG. 5 ). Instead, to secure the fasteners, a user accesses the web portion  106  of the curtain wall system.  
         [0046]     Referring now to  FIG. 5 , an assembly diagram of the support anchor  100  and vertical mullion  102  is shown. The support anchor  100  is attached to the web portion  106  of the vertical mullion  102  via fasteners  104  as illustrated above. The face cover  108  is attached by snapping over a pressure plate  110 . The pressure plate  110  is attached to the front face  106   a  of the web portion  106  via fasteners  111 . By attaching the support anchor  100  to the vertical mullion  102  in this manner, no penetration is made through the vertical mullion into a void  112  thereof. By not penetrating the void  112 , additional sealing of the vertical mullion  102  is not necessary when securing the support anchor  100 .  
         [0047]     Referring now to  FIGS. 6A and 6B  in combination, the support anchor  100  is shown secured to the vertical mullion  102 . The fasteners  104  are oriented such that panel members  300  (e.g., glass panels, marble panels, etc.) may reside within the web portion  106  without causing substantial damage to either the fasteners  104  or the panel members  300 . In a preferred embodiment, the panel members  300  are oriented so as to not be in direct contact with the fasteners  104 . Alternatively, or in addition, a gasket or padding member may be inserted between the fasteners  104  and the panel members  300  to prevent damage to the panel members  300 . The panel members  300  may be held in the web portion  106  with various arrangements that are known in the art and need not be discussed herein.  
         [0048]     Referring now to  FIGS. 7A and 7B  in combination, the support anchor  100  of an embodiment of the present invention is shown. The support anchor  100  includes a securement portion  400  and an anchor portion  402 . The anchor portion  402  may be utilized to support various pieces that may extend from the curtain wall system, such as sun shades. The securement portion  400  is utilized to secure the support anchor  100  to the web portion  106  of the vertical mullion  102 . The securement portion  400  is formed in a “hook” orientation to create a positive interlock and increase structural strength. The securement portion  400  includes a plurality of apertures  404  to allow securement of the support anchor  100  via fasteners  104 . The apertures  404  may be prefabricated along with apertures of the anchor portion  402  and the web portion  106 . Alternatively, apertures of the web portion  106  and support anchor  100  may be created at the job site.  
         [0049]     The apertures  404  of the securement portion  400  are formed within a channel  406 . The channel  406  may be sized as to create self-locking of the nuts of the fasteners  104 .  
         [0050]     Referring now to  FIG. 8 , a detailed top view of the support anchor  100  secured to the web portion  106  of the vertical mullion  102  is shown. The securement portion  400  of the support anchor  100  is oriented around a front face  106   a  of the web portion  106  and against a surface of the web portion  106 . As shown the fasteners  104  are oriented substantially transversely to a tension force T (indicated by an arrow) created at the support anchor  100 . In contrast to fasteners oriented in-line with the tension force T, the fasteners  104  of embodiments of the present invention may not be pulled out due to the tension force T.  
         [0051]     Referring now to  FIG. 9 , there is shown a flowchart of one embodiment of certain methods of the present invention. In the embodiment shown, the method is presented for supporting structures outwardly of the curtain wall of the type of vertical mullions formed with web sections extending outwardly thereof. The steps include forming ( 602 ) an anchor plate adapted to mount with the web section of the curtain wall and extend outwardly therefrom for support of structures therewith. The steps further include providing ( 604 ) the web with one of a hollow tongue configuration and an external flange portion, the web having a first set of fastening apertures formed therethrough. In step  606  the anchor plate is provided with a first set of mating apertures adapted for a registry with the first set of fastening apertures. In step  608  the anchor plate is provided with a second set of apertures for securing such structures outwardly of the curtain wall. Finally, step  610  comprises mounting the anchor plate into the web section of the curtain wall and securing the mounting thereof with threaded fasteners extending through the first set of fastening apertures formed in the web.  
         [0052]     Referring now to  FIGS. 10 and 11 , there are shown alternative embodiments of the present invention. In  FIG. 10 , a top view of the support anchor  100  secured to the web portion  106  of the vertical mullion  102  is shown. In this particular embodiment, the fastener  104  threadably engages the support anchor  100  with the support anchor  100  having a threaded aperture formed therethrough for receipt of the threaded fastener  104  therein. It may be seen that the securement portion  400 , in this particular embodiment, is thicker than that shown in  FIG. 8  and fully threaded for the receipt of the threaded fastener  104  therein. Likewise, in  FIG. 11 , the alternative embodiment includes a variation in the support anchor, wherein a support anchor  100 A is shown with a pair of support plates in generally parallel-spaced relationship. Support anchor  100 A is shown for purposes of illustrating the fact that variations in the shape, size and configuration of the support anchor may be made in accordance with the principles of the present invention.  
         [0053]     Although the support anchor is illustrated as having four apertures for connecting to other pieces, such as sunshades, it will be understood by one skilled in the art that more or less than four apertures in any orientation may be present on the support anchor. In addition, more or less fasteners may be utilized to secure the support anchor  100  to the web portion  106 . The anchor portion may also be formed in a variety of shapes other than that shown (i.e., rectangular, square, semi-circular, etc.). Furthermore, the securement portion may be oriented in a variety of shapes other than the “hook” orientation shown. For example, a forked securement portion may be utilized without departing from aspects of the present invention. The face plate may or may not be utilized in accordance with aspects of the present invention.  
         [0054]     While exemplary embodiment(s) of the present invention have been described, it should be recognized that the invention can be varied in many ways without departing therefrom. Because the invention can be varied in numerous ways, it should be understood that the invention should be limited only insofar as is required by the scope of the following claims.