Patent Publication Number: US-8973316-B2

Title: Sectional construction assemblies

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 60/724,996 filed in the United States Patent and Trademark Office on Oct. 7, 2005 by Franz Safford. 
    
    
     FIELD OF INVENTION 
     The present invention generally concerns systems and methods for assembling construction sections; and more particularly, representative and exemplary embodiments of the present invention generally relate to assembly and construction of glass panel walls. 
     BACKGROUND OF INVENTION 
     A variety of systems are used in the construction of buildings. Many of these systems employ a framework, such as in the case of conventional point-supported and conventional glass wall systems. In these systems, panes of glass are attached to, and supported by, an aluminum framework; however, such systems suffer from substantial drawbacks. 
     One problem presented by conventional glass wall systems is the need for significant structure to support the panes of glass. Existing systems often require both horizontal and vertical support members in order to provide structural integrity for retaining panes of glass making up the wall. Implementing such an extensive framework is often costly due, at least in part, to the amount of construction material required and the time needed to build the framework. Additionally, horizontal and vertical supports generally are connected together in a substantially unitary manner, and such restriction often limits architectural design options for an engineer or architect employing such a system. As a result, conventional glass wall systems have been constrained to substantially orthogonal frameworks. 
     Another problem involves the difficulty associated with constructing conventional point-support frameworks. For example, some systems require holes to be drilled in the glass panes in order to permit bolts to be inserted to attach the glass panels to the support structure. In generally, these holes typically are drilled with a relatively high degree of precision, or the pane of glass may not properly fit within the structure. Moreover, holes in the glass panels general present additional problems associated with sealing the glass wall from the exterior environment. Thus, the time and skill required to drill holes in the glass panes and mount the panes on existing framing systems becomes a substantial portion of the overall cost of implementing conventional point-supported glass wall systems. 
     The amount of structural support typically required in conventional glass wall systems also exacts a toll on the aesthetic properties of the framework system. While a glass wall with fewer supporting elements may give the appearance of a wall made nearly entirely of glass, the volume of columns, beams and other structural elements typically found in conventional point-supported glass walls often detract from their appearance and overall aesthetic appeal. Accordingly, what is needed is a system and method that addresses the deficiencies of conventional point-supported and conventional construction frameworks. 
     SUMMARY OF THE INVENTION 
     In various representative aspects, the present invention provides a system and method for the assembly and support of construction sections. Exemplary features generally include a guide track disposed within a mullion and a fitting that is suitably adapted for supporting a construction section, where the fitting is configured to hold and retain a construction section once the fitting is engaged within the guide track of the mullion. 
     Advantages of the present invention will be set forth in the Detailed Description which follows and may be apparent from the Detailed Description or may be learned by practice of exemplary embodiments of the invention. Still other advantages of the invention may be realized by means of any of the instrumentalities, methods or combinations particularly pointed out in the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Representative elements, operational features, applications and/or advantages of the present invention reside inter alia in the details of construction and operation as more fully hereafter depicted, described and claimed—reference being made to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout. Other elements, operational features, applications and/or advantages will become apparent in light of certain exemplary embodiments recited in the detailed description, wherein: 
         FIG. 1  representatively illustrates a three-quarter isometric view of a fitting attached to a mullion in accordance with an exemplary embodiment of the present invention; 
         FIG. 2  representatively illustrates top cross-sectional and three-quarter isometric views of a mullion in accordance with an exemplary embodiment of the present invention; 
         FIG. 3  representatively illustrates top cross-sectional views of various mullion embodiments in accordance with exemplary aspects of the present invention; 
         FIG. 4  representatively illustrates a three-quarter isometric view of a mullion splice configuration in accordance with an exemplary embodiment of the present invention; 
         FIG. 5  representatively illustrates a three-quarter isometric view of a dual guide channel anchor bracket and associated fitting in accordance with an exemplary embodiment of the present invention; 
         FIG. 6  representatively illustrates side cross-sectional views of a plurality of fitting engagement mechanisms in accordance with various exemplary embodiments of the present invention; 
         FIG. 7  representatively illustrates a three-quarter isometric view of a pinch-plate fitting that may be attached to the guide track of a mullion in accordance with an exemplary embodiment of the present invention; 
         FIG. 8  representatively illustrates a three-quarter isometric view of a shelf fitting attached to the guide track of a mullion in accordance with an exemplary embodiment of the present invention; 
         FIG. 9  representatively illustrates a three-quarter isometric view of a jamb channel fitting attached to a guide track integrated into the jamb channel in accordance with an exemplary embodiment of the present invention; 
         FIG. 10  representatively illustrates a three-quarter isometric view of a pinch-plate, shelf-mount combination fitting in accordance with an exemplary embodiment of the present invention; 
         FIG. 11  representatively illustrates a side cross-sectional view of a hanger fitting in accordance with an exemplary embodiment of the present invention; 
         FIG. 12  representatively illustrates a three-quarter isometric view of two mullions attached in accordance with an exemplary embodiment of the present invention; 
         FIG. 13  representatively illustrates a three-quarter isometric view of a door/window hinge fitting having a movable assembly for attachment of a window to the guide track of a mullion in accordance with an exemplary embodiment of the present invention; and 
         FIG. 14  representatively illustrates a three-quarter isometric view of a fire safe construction design assembly in accordance with an exemplary embodiment of the present invention. 
     
    
    
     Elements in the Figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the Figures may be exaggerated relative to other elements to help improve understanding of various embodiments of the present invention. Furthermore, the terms “first”, “second”, and the like herein, if any, are used inter alia for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. Moreover, the terms “front”, “back”, “top”, “bottom”, “over”, “under”, “forward”, “aft”, and the like in the Description and/or in the claims, if any, are generally employed for descriptive purposes and not necessarily for comprehensively describing exclusive relative position. Any of the preceding terms so used may be interchanged under appropriate circumstances such that various embodiments of the invention described herein, for example, may be capable of operation in other configurations and/or orientations than those explicitly illustrated or otherwise described. 
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     The following representative descriptions of the present invention generally relate to exemplary embodiments and the inventor&#39;s conception of the best mode, and are not intended to limit the scope, applicability or configuration of the invention in any way. Rather, the following description is intended to provide convenient illustrations for implementing various embodiments of the invention. As will become apparent, changes may be made in the function and/or arrangement of any of the elements described in the disclosed exemplary embodiments without departing from the spirit and scope of the invention. 
     Various representative implementations of the present invention may be applied to any system for construction. Certain representative implementations may include systems and methods tailored to a specific type of construction, such as point-supported glass wall systems. A detailed description of an exemplary application, namely a construction system for point-supported glass-paned walls, is provided as a specific enabling disclosure that may be generalized to any application of the disclosed systems, devices and methods for construction in accordance with various embodiments of the present invention. 
     As generally depicted in  FIG. 1 , a representative embodiment of an exemplary construction system  100  generally comprises a mullion  110  having a guide track  120  disposed along at least one dimension of mullion  110 . Guide track  120  may be disposed along a substantially linear length of mullion  110  and may be suitably adapted for adjustable engagement with fitting  130 . Fitting  130  may be adjusted along the guide track  120  and substantially fixed in place at any point along guide track  120 . Fitting  130  may be suitably configured to support any type of construction section, such as a pane of glass. 
     Mullion  110  is generally configured for engagement with fitting  130  and provides support for a construction section held in place by fitting  130 . Mullion  110  may comprise any material, such as, for example: metal; polymer; graphite; alloy; wood; composites and/or any other types of material, whether now known, hereafter discovered or otherwise subsequently described in the art. Mullion  110  may also comprise any structural or design features that may be employed to allow for the attachment of fitting(s)  130  for providing support and/or retention of construction sections. Construction sections may comprise, for example: wood; ceramic; glass; polymer sheeting; bullet-proof glass; synthetic paneling and/or any other type of material, whether now known, hereafter discovered or otherwise subsequently described in the art. 
     Mullion  110  may be fabricated using any method of manufacture known in the art and may include any number of suitable materials, such as aluminum, steel, graphite, composite and/or the like. In an exemplary embodiment, for example, mullion  110  may be fabricated from forged or extruded aluminum. In another embodiment, according to various representative aspects of the present invention, mullion  110  may comprise a steel rod configured for attachment to a fitting suitably adapted to support a shelf plate. In such an embodiment, the rod may provide anchoring support of the shelf plate, and the shelf plate may be configured to at least partially support, for example, panes of glass at the corner edges of a glass wall. 
     Mullion  110  comprises a first end  112  that may be positioned towards the interior of a structure being constructed. A connecting projection  114  may be provided to join the first end  112  with a second end  116  of mullion  110 . Mullion  110  may also comprise a guide channel  120  substantially disposed on second end  116 . Guide channel  120  may be positioned, for example, towards the exterior of a structure being constructed using the disclosed systems and methods, and may provide suitable anchor points for attachment of fitting(s)  130  that subsequently operate to retain and support a construction section. In such an exemplary embodiment, the depicted structure of mullion  110  allows it to support the weight of the construction section held by fitting  130 . Additionally, mullion  110  may permit translational or rotational motion in response to environmental effects, such as wind, rain and/or thermal expansion or contraction. 
     Referring now to  FIG. 2 , mullion  210  generally comprises a structure having one or more void cavities  230  and a guide channel  220 . Cavity  230  may be of any volume or shape and may be disposed within any part of mullion  210 . For example, mullion  210  may comprise a plurality of cavities with intervening structures between the void cavities, for example, in order to increase the load bearing strength of mullion  210 . 
     Alternatively, conjunctively or sequentially, referring now to  FIG. 3 , a substantially unitary cavity  210  (such as represented in the depicted exemplary embodiments  300 ,  310 ,  320 ,  330 ,  340 ,  350 ,  360 ,  370 ,  380 ) may be formed at least partially along the top cross-sectional face of a mullion, for example, to reduce weight and/or material cost, as well as to provide the mullion with the ability to react to forces, such as expansion or contraction in response to thermal variations. Mullions  300 ,  310 ,  320 ,  330 ,  340 ,  350 ,  360 ,  370 ,  380  may also be configured with one or more variously disposed guide channels  220 ,  220   a ,  220   b.    
     Mullion  110  may interface with or be joined to other mullions in any suitable manner. Mullion  110  may connect with any suitable structures, systems and devices in any suitable manner to achieve any particular purpose. Mullion  110 , in accordance with various aspects of the present invention, may be suitably configured for attachment to a surface such as a floor, wall and/or the like. Mullion  110  may be attached to any suitable surface in any suitable manner, and may be configured to support any structure, system, device or architectural element in any suitable manner. For example, in an exemplary embodiment of the present invention, the structure of mullion  110  may comprise a guide channel  120  that operates inter alia to provide attachment and support for panes of glass. Mullion  110  may be adapted to include any other suitable features, such as weep holes to allow moisture to drain away from the guide track  120  of mullion  110 , or any other design features whether now known or hereafter described in the construction art. 
     In another exemplary embodiment, referring now to  FIG. 4 , a plurality of mullions may be connected using a splice plate  410 . Splice plate  410  may be generally configured to permit the attachment of two or more mullions in any suitable manner, such as for example, with the use of nuts and bolts as generally depicted in  FIG. 4 . Splice plate  410  may comprise any suitable size, shape, configuration, geometry and/or symmetry. In an exemplary embodiment in accordance with the present invention, splice plate  410  may be configured to conform to the recessed area  420  disposed between the first end  112  and the second end of the mullion. Spliced plate  410  may be disposed or otherwise configured for disposal substantially internal to the mullion. Splice plate  410  may be adapted to provide attachment to the connecting projection  114  of the mullions to hold them together. 
     In another exemplary embodiment, referring now to  FIG. 5 , anchor plate  510 , according to various representative aspects of the present invention, may include two or more guide tracks  520   a ,  520   b . Anchor plate  510  may be configured to interface with plate fitting  530 , which may comprise an anchor plate assembly suitably adapted to support any type of structure or design element (e.g., a construction section and/or the base of a mullion). Plate fitting  530  may include a substantially vertical plate  540  having a hole  532  disposed therethrough, which may operate as a mounting feature for securing structural attachment(s), such as in the case of using a bolt to attach a structural element to vertical plate  540 . Anchor plate  510  may be suitably connected to any surface in any manner, whether now known or otherwise hereafter described in the art. For example, anchor plate  510  may be attached to a floor using bolts  520 . The position of plate fitting  530  may be adjusted along the length of guide tracks  520   a ,  520   b  as well as slots  560  and attached to anchor plate  510  using bolts  550  and clamp nuts  570 . 
     In general, guide channels generally enable the fittings to be connected to the mullion. The guide channels may be fabricated from any material, whether now known or otherwise hereafter described in the art. Guide tracks may comprise any shape, size or configuration and may include any number of sub-systems and/or design features to achieve any particular purpose. For example, in the embodiment generally depicted in  FIG. 1 , guide track  120  may comprise a lip-rail channel integrated within the structure of mullion  110 . Additionally, mullion  110  may comprise multiple guide tracks  120  suitably adapted for any particular purposes. As shown in the exemplary embodiment illustrated in  FIG. 5 , for example, anchor plate  510  may include multiple guide channels  520   a ,  520   b . In an alternative, conjunctive or sequential exemplary embodiment, referring now to  FIG. 6 , guide track  120  may comprise a groove or raceway  610  formed substantially within the interior of mullion  110 . (See, for example, embodiment  600 ). Groove  610  may be configured to suitably support fitting  630  in any suitable manner, such as in the case of using a screw  612  to anchor fitting  630  in groove  610 . In another exemplary embodiment  602 , the guide track may comprise an extruded rail structure  620  (as compared with, for example, an intruded rail structure  650 ). In this exemplary embodiment, fitting  630  may include a jacket structure  622  that engages and fits around rail structure  620 . Fitting  630  may be generally attached to rail structure  620  in any suitable manner, such as by using a set screw  624 . In an alternative exemplary embodiment  604 , in accordance with various aspects of the present invention, the guide track may comprise a fin structure  636 . Fin  636  may be configured to support fitting  630  in any suitable manner, such as by adapting fitting  630  to retain and support a pinch plate  632  held to fin structure  636  using bolt  634 , for example. The Guide track may include any suitable structure, such as a fastener  640  that holds fitting  630  to mullion  110 . (See embodiment  606 ). The Guide track in various other embodiments may be attached to mullion  110  in any manner, whether now known or otherwise hereafter described in the art. For example, the guide track may comprise an intruded rail  650  attached to mullion  110 , which may be suitably adapted to retain and support fitting  630  as shown in exemplary embodiment  608 . 
     Fitting  630  may be generally configured for attachment to mullion  110  and may be suitably adapted to retain and support a construction section. Fitting  630  may include any number of sub-systems, structures and/or devices to achieve any particular purpose. 
     In an exemplary embodiment, referring now to  FIG. 7 , fitting  130  may include a pinch plate sub-system  700  comprising a clamp nut  725  and screw  724  configured to attach the inner fitting  705  to the guide track  120  of mullion  110 . A construction section may be retained and supported, for example, between the cap  720  and the inner fitting  705  using studs  722 , cap nuts  726 , screw  724  and the clamp nut  725  to provide (once assembled) suitable pressure against a point-supported face of a construction section (e.g., glass panel). 
     Fitting  130  may be adapted to support a construction section in any manner, whether now known or hereafter described in the art. For example, referring now to  FIG. 8 , fitting  830  may include a shelf feature  810 . Shelf  810  may be configured to support a construction section in any manner, such as via bearing the weight of a pane of glass resting on top of shelf  810 . Alternatively or conjunctively, shelf  810  may be suitably adapted to run substantially parallel to mullion  110  in order to provide horizontal support for a construction section. Similarly, fitting  830  may be configured in any manner to hold a construction section at any angle. For example, fitting  130 / 830  may include angled and/or curved structures to allow a construction section to be supported by the fitting at various angles and positions with respect to orientation of the mullion  110 . Shelf  810  may comprise any configuration that may be employed for any particular purpose, whether now known or otherwise hereafter described in the art. For example, referring now to  FIG. 9 , the shelf structure may include a jamb shelf  940  configured for attachment to the guide channel  920  of channel/mullion  910 . In this case, jamb shelf  940  may be adapted to support and retain, for example, a pane of glass  930 . 
     Fittings in accordance with various representative embodiments of the present invention may include any structure, sub-system and/or device suitably configured to support a construction section in any manner for any particular purpose, whether now known or otherwise hereafter described in the art. For example, referring again to  FIG. 1 , fitting  130  may include a base  132  and a shelf plate  134 , where the shelf plate  134  is substantially removably attachable to the base  132 . In such an embodiment, fitting base  132  may attach to any number of modular systems, devices and/or fasteners that are suitably adapted for holding construction sections. 
     Referring now to  FIG. 10 , an exemplary fitting according to various aspects of the present invention may comprise a combination pinch plate and shelf fitting  1000  having a pinch plate  1010 , cap nuts  1012 , studs  1014  and a shelf plate  1020 . Shelf plate  1020  may be suitably adapted to support a construction section substantially vertically, while pinch plate  1010  may be configured to support a construction section in place using, for example, cap nuts  1012  and studs  1014 . Shelf fitting  1000  may be suitably configured for attachment to mullion  110 , for example, using bolt  1030  and channel clamp nut  1040 . 
     In another exemplary embodiment in accordance with various aspects of the present invention (referring now to  FIG. 11 ), fitting  130  may comprise a hanger mount assembly  1100 . Hanger mount  1100  may include a plate  1120  having a support hole  1130  disposed therethrough. Hanger mount  1100  may be suitably configured for attachment to mullion  110  via bolts  1110  and nuts  1115 . Hanger mount  1100  may be further adapted to support any sub-system, structure and/or construction section in any manner, whether now known or otherwise hereafter described in the art. For example, a plurality of hanger mounts  1100  may be used to support a canopy by connecting hanger mounts  1100  on a canopy to hanger mounts  1100  on a glass wall, for example, using cables. Hanger mount  1100  may include any number of structures and/or sub-systems in any configuration. For example, hanger mount  1100  may have a plurality of support holes  1130  that anchor, for example, an awning or sun shade extension having louvered blades. Similarly, hanger mount  1100  may support a canopy blade extension. 
     Fitting  130  may interface with any structures, sub-systems and/or devices to achieve any particular purpose. Referring now to  FIG. 12 , a horizontally disposed mullion  1210  may be suitably attached to the guide channel  230  of a vertically disposed mullion  1220  using a fitting  130  to form a horizontal support. Any other suitable structure, system and/or device may also interface with guide channel  230  in any suitable manner or configuration. In another embodiment, for example, referring now to  FIG. 13 , fitting  130  includes a hinge assembly  1300 . Hinge assembly  1300  may be configured to suitably retain and support a construction section, such as a window or door  1310  while allowing the window or door  1310  to open and close. In such an embodiment, head extrusion  1320  may be adapted to attach to the mullion thereby permitting the window/door  1310  to close against edge frame  1330 . 
     Referring now to  FIG. 14 , glass pane  1400  may be retained and supported relative to guide track  1440 , mullion  210  and fitting  1490  via operational engagement of cap nut  1410  with pinch plate  1420  and threaded stud  1430 . For safety applications, guide track  1440  may be packed with, for example, mineral wool batting  1450  in order to reduce the risk of fire. The fire proofing material  1450  (e.g., mineral wool batting) may comprise additional fill material  1470  that intrudes into the main structural support material as representatively depicted in the overlap  1460  shown in  FIG. 14 . The fill material  1470  and fire proofing material  1450  may thereafter be enclosed with, for example, a metal trim closure  1480  to retain the materials or otherwise prevent them from being exposed to the external environment. 
     The disclosed construction system may also be suitably adapted to provide a dual or plural glass panel. In a representative embodiment, a first glass panel may be disposed substantially exterior to the mullion and a second (or subsequent) glass panel may be disposed substantially interior to the mullion with an air-gap therebetween. This would provide inter alia improved acoustic dampening and energy efficiency. 
     The disclosed construction system may also be suitably adapted to provide a hurricane resistant glazing system attached to the front of the mullion. In this configuration, fitting  130  may be modified to provide a hook structure suitably configured to support a framed glass panel—for example, with a relatively small aluminum edge frame of the panel continuously supporting the glass construction section. The assembled panel would subsequently offer “point-supported” retention at the hook fittings. Such a system would be particularly well adapted to satisfy large projectile impact requirements of building materials in, for example, hurricane conditions. 
     In a construction system according to various aspects of the present invention, mullions may be attached to the structure of a building to provide a framework for supporting construction sections. Suitably configured fittings may be attached to the mullions to provide point-supported or continuously supported retention of construction sections. Construction systems in accordance with various exemplary embodiments of the present invention may be used to build any type of structure, whether now known or hereafter described in the art, such as a point-supported glass wall, for example. The construction system may also be used to achieve various aesthetic benefits. For example, the panes of glass used to form a glass wall will generally be displaced away from the mullions, making it more difficult to see the mullions from an exteriorly disposed vantage point. Additionally, construction systems in accordance with the present invention may be used to achieve any structural benefit, whether now known or hereafter described in the art, such as the ability to construct a multi-story point-supported glass wall system using substantially vertically-aligned mullions without the need for horizontally-aligned mullions. 
     Constructs (i.e., construction designs) that may be realized via implementation of various embodiments of the present invention shall be understood to comprise anything that may be at least partially assembled from at least one or more component parts, such as, for example: a window; a wall; a partition; a frame; a panel; a covering; a dome; a door; a display case; a display wall; a display frame; a cubicle; a presentation display; a booth; an enclosure; a temporary habitat; a mobile home; a video device array; various architectural construction elements; and/or the like. 
     A ‘construction section’ shall be understood to comprise any component part of a construct surface, such as, for example, a pane of glass, a panel of wood, a sheet of drywall, a graphite board, Plexiglas, Lucite, a video device element, etc. Furthermore, a construction section may comprise any two-dimensional (e.g., substantially planar) or three-dimensional (e.g., polyhedral, spherical, hemispherical, elliptical, parabolic, etc.) geometry and/or any combination thereof. 
     In the foregoing specification, the invention has been described with reference to specific exemplary embodiments; however, it will be appreciated that various modifications and changes may be made without departing from the scope of the present invention as set forth in the claims below. The specification and Figures are to be regarded in an illustrative manner, rather than a restrictive one and all such modifications are intended to be included within the scope of the present invention. Accordingly, the scope of the invention should be determined by the claims appended hereto and their legal equivalents rather than by merely the examples described above. 
     For example, the steps recited in any method or process claims may be executed in any order and are not limited to the specific order presented in the claims. Additionally, the components and/or elements recited in any apparatus claims may be assembled or otherwise operationally configured in a variety of permutations to produce substantially the same result as the present invention and are accordingly not limited to the specific configuration recited in the claims. 
     Benefits, other advantages and solutions to problems have been described above with regard to particular embodiments; however, any benefit, advantage, solution to problem or any element that may cause any particular benefit, advantage or solution to occur or to become more pronounced are not to be construed as critical, required or essential features or components of any or all the claims. 
     As used herein, the terms “comprise”, “comprises”, “comprising”, “having”, “including”, “includes” or any variation thereof, are intended to reference a non-exclusive inclusion, such that a process, method, article, composition or apparatus that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such process, method, article, composition or apparatus. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials or components used in the practice of the present invention, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters or other operating requirements without departing from the general principles of the same.