Abstract:
A curtain wall system and method facilitates the installation of exterior and interior curtain walls. Brackets are mounted at equally spaced vertical intervals receive and secure curtain wall members installed from the top of the wall down. A kerf formed in the lower end of each wall member is received on a receiving and retaining member located at the distal end of the supporting member of each bracket. A kerf formed in the upper end of the wall member receives a locating and retaining member having a latch secured thereto. The wall member and the latch are then rotated towards the bracket until the latch engages with a locking member of the bracket, thereby securing the wall member in place.

Description:
CLAIM OF PRIORITY  
       [0001]     This application claims priority of prior provisional Application Ser. No. 60/565,445 filed Apr. 26, 2004. 
     
    
     TECHNICAL FIELD  
       [0002]     This invention relates generally to curtain walls and methods of installing the same, and more particularly to an improved system for facilitating the installation of curtain walls formed from limestone and similar materials.  
       BACKGROUND AND SUMMARY OF THE INVENTION  
       [0003]     U.S. Pat. No. 5,473,851 discloses a method of installing curtain walls formed from limestone and similar materials on exterior and interior building walls. The present invention comprises a curtain wall installation system and method which improves upon the curtain wall system of the &#39;851 patent and other prior art curtain wall systems and methods.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0004]     A more complete understanding of the present invention may be had by reference to the following Detailed Description when taken in connection with the accompanying Drawings, wherein:  
         [0005]      FIG. 1  is an environmental view illustrating a curtain wall system installed in accordance with the method of the present invention;  
         [0006]      FIG. 2  is an illustration of a curtain wall constructed in accordance with the present invention; and  
         [0007]      FIG. 3  is an illustration of the curtain wall installation method of the present invention.  
         [0008]      FIG. 4  is a perspective view illustrating an initial step in the utilization of the curtain wall installation method of the present invention;  
         [0009]      FIG. 5  is a perspective view illustrating a later step in the utilization of the curtain wall installation method of the present invention;  
         [0010]      FIG. 6  is a perspective view illustrating a somewhat later step in the utilization of the curtain wall installation method of the present invention;  
         [0011]      FIG. 7  is a perspective view illustrating a still later step in the utilization of the curtain wall installation method of the present invention; and  
         [0012]      FIG. 8  is a perspective view illustrating an even later step in the utilization of the curtain wall installation method of the present invention.  
     
    
     DETAILED DESCRIPTION  
       [0013]     Referring to  FIGS. 1 and 2 , there is shown a curtain wall  10  constructed in accordance with the present invention. The curtain wall  10  is supported on a wall  12  which may be comprised of one or more layers of plywood  14 . Other construction techniques may be utilized in the fabrication of the wall  12  depending upon the requirements of particular applications of the invention. The wall  12  may comprise an exterior wall of a building or other structure. In such instances the wall  12  is preferably provided with a weather proof exterior layer  16  which is fabricated in accordance with conventional techniques.  
         [0014]     In accordance with the present invention a plurality of brackets  18  are secured to the wall  12  by suitable fasteners  20 . The brackets  18  may be fabricated from aluminum, however, other materials may be utilized in the fabrication of the brackets  18  depending upon the requirements of particular applications of the invention. A plurality of brackets  18  may be positioned adjacent to one another to define a curtain wall support structure which extends substantially the entire width of the wall  12 . Alternatively, brackets  18  may be positioned at spaced apart locations along the width of the wall  12 .  
         [0015]     Each bracket  18  includes a curtain wall supporting member  22  which extends perpendicularly outwardly from the wall  12 . A curtain wall receiving and retaining member  24  is located at the distal end of the curtain wall support member  22  and extends perpendicularly upwardly therefrom. The bracket  18  is further provided with a locking member  26  and a stop  28 .  
         [0016]     A plurality of curtain wall members  30  are formed from limestone or similar materials. For example, the curtain wall members may be formed from granite, marble, terrazzo, etc. Each curtain wall member  30  has a kerf  32  formed in the lower end thereof and a kerf  34  formed in the upper end thereof.  
         [0017]     Following installation, each curtain wall member  30  is supported by the supporting member  22  of the associated bracket  18  which is in turn secured to the wall  12  by the fasteners  20 . The receiving and retaining member  24  of the bracket  18  is received in the kerf  32  of the curtain wall member  30  which is supported on the bracket  18 . In this manner the wall member  30  is located and positioned relative to the wall  12  by the bracket  18 .  
         [0018]     In accordance with the present invention a latching member  36  is utilized in conjunction with the bracket  18 . The latching member  36  includes a horizontally disposed portion  38  which extends parallel to the supporting member  22  of the bracket  18 . Knobs  40  formed on the horizontally disposed portion  38  maintain proper alignment between the horizontally disposed portion  38  and the supporting member  22 .  
         [0019]     The horizontally disposed portion  38  of the latching member  36  extends to an arrow-shaped latch  42  positioned for latching engagement with the locking member  26  of the bracket  18 . The distal end of the latch  42  is positioned closely adjacent to and in alignment with the stop  28  of the bracket  18 . A locating and retaining member  44  is located at the opposite end of the horizontally disposed portion  38  of the latching member  36  and extends perpendicularly with respect thereto. The locating and retaining member  44  is received in the kerf  34  situated at the upper end of the corresponding curtain wall member  30 . Once two adjoining wall members  30  are secured in place, joint sealant  46  is applied between the wall members  30  to provide additional strength and stability to the wall members and to provide a cushion allowing some movement by the wall members  30  due to foundation settlement, earthquakes, hurricanes and the like.  
         [0020]     The method of curtain wall installation of the present invention is illustrated in  FIG. 3 . An upper curtain wall member  30  is first supported on a bracket  18  constructed in accordance with the present invention with the receiving and retaining member  24  received in the kerf  32  thereof and with the upper curtain wall member supported on the curtain wall supporting member  22 . The latching member  36  is engaged with a lower curtain wall member  30  by positioning the locating and retaining member  44  thereof in the kerf  34  of the lower curtain wall member  30 . The lower wall member  30  is then pivoted inwardly toward the bracket  18  in the direction of the arrow. As the lower curtain wall member  30  moves into position, the arrow-shaped latch  42  of the latching member  36  moves past the locking member  26  of the bracket  18  thereby securing the lower curtain wall member  30  in place. Further inward movement of the lower curtain wall member  30  is prevented by engagement of the distal end of the latch  32  with the stop  28  of the bracket  18 .  
         [0021]     Foam tape  48  secured beneath the proximal end of the horizontally disposed member  38  compresses to allow the latching member  36  and the arrow-shaped latch  42  to rotate into the locking member  26  of the bracket  18 . Once the latching member  36  is locked in place in the locking member  26 , the foam tape  48  decompresses thereby holding the latching member  36  snugly against the support member  22  until the joint sealant  48  sets to permanently hold the latching member  36  in place.  
         [0022]      FIG. 4  illustrates the preliminary step of the curtain wall installation method of the present invention. Brackets  18  are secured to the wall  12  by suitable fasteners at spaced intervals substantially equal to the height of each wall member  30 . At the base of the wall, a bottom bracket  50  is mounted to receive the a lower-most wall member  30  to be mounted on the wall  12 . The bottom bracket  50  is substantially similar in construction to the bracket  18  but comprises only a support member  22  and a receiving and retaining member  24  on the distal end thereof. A top bracket  52  is mounted to receive the uppermost wall member  30  to be mounted on the wall  12 . The top bracket is similar in construction to the bracket  18  but comprises only a support member  22 , a stop  28 , and a locking member  26 .  
         [0023]     Referring now to  FIGS. 5 through 7 , there is shown the next steps in the curtain wall installation method of the present invention preparing the wall member  30  for mounting. As best shown in  FIG. 5 , the kerfs  32  are 34 are formed in the lower and upper ends of the wall member  30 . A silicon sealant  54  is applied into the kerfs  32  and  34  as shown in  FIG. 6 . As best shown in  FIG. 7 , once the sealant  54  is applied, foam tape  48  is secured below the distal end of the horizontally disposed portion  38  of the latching member  36  after which the locating and retaining member  44  is inserted into the kerf  32  in the upper end of the wall member  30 .  
         [0024]     Referring now to  FIG. 8 , the wall members  30  are installed beginning at the top of the wall  12  and proceeding downward therefrom. Once the wall member  30  is prepared, the kerf  34  in the lower end of a wall member  30  is received in the receiving and retaining member  24  of the support member  22  located near the lower end of the wall member  30 . The wall member  30  is then pivoted inwardly toward the bracket  18  in the direction of the arrow. As the lower curtain wall member  30  moves into position, the arrow-shaped latch  42  of the latching member  36  moves past the locking member  26  of the bracket  18  thereby securing the lower curtain wall member  30  in place. Once the curtain wall members  30  are in place the silicon sealant  46  is placed between the wall members  30 .  
         [0025]     The present invention is illustrated in conjunction with the construction of curtain walls wherein the wall members  30  are formed of limestone, stone, and other like materials. However, the present invention is equally applicable to constructing walls comprising tile, porcelain, wood and various other materials used for wall curtains both on interior and exterior walls.  
         [0026]     Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention.