Patent Publication Number: US-10309150-B2

Title: Structural glazing weather seal with captured glazing option

Description:
FIELD 
     The present invention relates to apparatus and methods for sealing joints between adjacent glazing panels of a glazed panel wall construction on the exterior of a building, such as a curtain wall, storefront or the like, and more particularly, to a pre-formed seal. 
     BACKGROUND 
     Various apparatus and methods for establishing a seal between glazing panels are known. Typically, two-sided silicone structural glazing (SSG) is sealed with a wet-type seal, e.g., a silicone seal that is applied in a flowable state and that subsequently cures to a non-flowable state. Preformed gaskets are known that install between adjacent glass panels. For example, U.S. Pat. No. 5,245,808 discloses a weather seal retainer for structural glazing. A pre-formed gasket is also known that may be inserted between glazing panels, see PG123™ wall system from Kawneer, http://www.kawneer.com. Notwithstanding, alternative apparatus and methods for sealing glazing panels remain desirable. 
     SUMMARY 
     The disclosed subject matter relates to a weather seal for a gap between adjacent glazing panels held to a structure, having: a first wall along the length of the weather seal; a first coupling disposed along a first side of the first wall, the first coupling attaching to the structure between the gap; a second coupling disposed along a second side of the first wall distal to the first side, the second coupling capable of selectively attaching to a cap covering the joint; at least one seal member extending from the first wall intermediate the first coupling and the second coupling, the seal member at least partially bridging the gap. 
     In another embodiment, the first coupling is a first receiver and the structure has a tongue that inserts into the first receiver. 
     In another embodiment, further including a second wall extending next to the first wall along the length of the first wall, the first wall and the second wall joined by a web. 
     In another embodiment, the at least one seal member includes a first fin and a second fin, the first fin extending from the first wall in a direction perpendicular thereto and distal to the second wall, the second fin extending from the second wall in a direction perpendicular thereto, and distal to the first wall. 
     In another embodiment, the at least one seal member further includes at least one sealing bulb, the sealing bulb having a hollow therein and capable of deforming when pressed into the gap. 
     In another embodiment, the at least one sealing bulb includes a first sealing bulb and a second sealing bulb, the first sealing bulb extending from the first wall in a direction perpendicular thereto and distal to the second wall, the second sealing bulb extending from the second wall in a direction perpendicular thereto, and distal to the first wall. 
     In another embodiment, the first sealing bulb and the second sealing bulb have a cross-section approximating an egg shape, with a first portion having a smaller diameter than a second portion, the first portions leading the first and second sealing bulbs into the gap before the second portions when the weather seal is installed in the gap. 
     In another embodiment, the second coupling is a second receiver and further including an extension from a wall of each of the sealing bulbs, the extensions extending in a direction toward one another to define a split over the second receiver. 
     In another embodiment, the weather seal is made from an elastic material, the first receiver capable of deforming to a first position capable of receiving the tongue of the structure and resiliently returning to a second position interlocking with the tongue of the structure. 
     In another embodiment, further including a first pair of inwardly directed prominences proximate the first receiver, a first prominence of the first pair extending from the first wall toward the second wall and a second of the first pair extending from the second wall toward the first wall, wherein the tongue of the structure has recesses on opposing sides thereof, the pair of prominences extending into the recesses when the tongue of the structure is inserted into first receiver in snap-fit relationship. 
     In another embodiment, further including an elongated cap capable of covering the gap, the cap having a front wall with a tongue extending therefrom, wherein, the second receiver is capable of deforming to a first position receiving the tongue of the cap and resiliently returning to a second position interlocking with the tongue of the cap and further including a second pair of inwardly directed prominences proximate the second receiver, a first prominence of the second pair extending from the first wall toward the second wall and a second prominence of the second pair extending from the second wall toward the first wall, wherein the tongue of the cap has recesses on opposing sides thereof, the second pair of prominences extending into the recesses in the tongue of the cap when the tongue of the cap is inserted into the second receiver in snap-fit relationship. 
     In another embodiment, the extensions form a shallow V shape in cross-section, the slit at the nadir of the V shape and disposed over and in alignment with the second receiver. 
     In another embodiment, further including a pair of inwardly extending guide beads in the first receiver for controlling the frictional interaction of the receiver with the tongue of the structure. 
     In another embodiment, a glazing structure includes: a glazing support member with a coupling member extending there from; a pair of glazing panels attached to the glazing support member with a gap there between; a weather seal inserted into the gap bridging between the pair of glazing panels, the weather seal having a first wall along the length thereof with a first coupling disposed along a first side, the first coupling attaching to the coupling member between the gap, a second coupling disposed along a second side of the first wall distal to the first side and a seal member extending from the first wall to at least one of the glazing panels. 
     In another embodiment, the first coupling and the second coupling are first and second receivers and the coupling member is a tongue that inserts into the first receiver, the weather seal further including a second wall extending next to the first wall along the length of the first wall, the first wall and the second wall joined by a web forming an H-shape in cross-section, wherein the seal member includes a pair of sealing fins, a first fin extending from the first wall in a direction perpendicular thereto and distal to the second wall, a second fin extending from the second wall in a direction perpendicular thereto, and distal to the first wall, and further comprising a pair of sealing bulbs having a hollow therein and capable of deforming when pressed into the gap, a first of the pair of sealing bulbs extending from the first wall in a direction perpendicular thereto and distal to the second wall, the second sealing bulb extending from the second wall in a direction perpendicular thereto, and distal to the first wall. 
     In another embodiment, the first sealing bulb and the second sealing bulb have a cross-section approximating an egg shape, with a first portion having a smaller diameter than a second portion, the first portions leading the first and second sealing bulbs into the gap before the second portions when the weather seal is installed in the gap, further including an extension from a wall of each of the sealing bulbs, the extensions extending in a direction toward one another and meeting to define a split over the second receiver. 
     In another embodiment, further including an elongated cap capable of covering the gap, the cap having a front wall with a tongue extending therefrom, the tongue of the cap being received in snap-fitting relationship into the second receiver. 
     In another embodiment, a method for sealing a gap between glazing panels, includes the steps of: providing a structure for supporting at least two glazing panels adjacent to each other with a gap between, the structure having a coupling member extending into the gap; providing an elongated weather seal having a first coupling disposed along a first longitudinal side and a second coupling disposed along a second longitudinal side and a seal member extending in a generally perpendicular direction relative the length of the weather seal, the weather seal having a penetrable barrier covering the second coupling; inserting the weather seal into the gap; coupling the first coupling of the weather seal to the coupling member of the structure, weather seal being held in position in the gap with the seal member at least partially bridging a width of the gap. 
     In another embodiment, further including the steps of providing an elongated cap with a front wall with a tongue extending therefrom; pushing the tongue of the cap into the second receiver; interlocking the tongue of the cap with the second receiver. 
     In another embodiment, further including the step of penetrating the penetrable barrier of the weather seal prior to the step of pushing and deforming the second receiver prior to the step of interlocking. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present disclosure, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings. 
         FIG. 1  is a perspective view of a weather seal in accordance with an embodiment of the present disclosure. 
         FIG. 2  is a cross-sectional view of the weather seal of  FIG. 1 , taken along section line  2 - 2  and looking in the direction of the arrows. 
         FIG. 3  is cross-sectional view of a glazing support structure and glazing panels on which the weather seal of  FIGS. 1 and 2  is installed. 
         FIG. 4  is a cross-sectional view of the structure of  FIG. 3 , further including a cap. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     An aspect of the present disclosure is the recognition that it would be beneficial to have a preformed weather seal for sealing a joint between adjacent glazing units that allows a cap structure to be attached to the joint at a predetermined relative position, e.g., parallel to and centered over the jot and without use of a flowable (liquid) sealant, such as silicone seal to attach the cap. 
     An aspect of the present disclosure is to provide a multi-function rain screen gasket. In one embodiment, the rain screen gasket includes a resiliently flexible front face and resiliently flexible back fins to provide two mechanisms to resist water penetration. In an embodiment, the rain screen gasket includes at least two retainer snaps, an interior retainer snap, which fixes the gasket to the face of a mullion, i.e., between two glass lites (glazing panels), and an exterior retainer snap to fix an exterior cover to the gasket for aesthetic and sealing purposes. 
     According to aspects of the present disclosure, an assembly is disclosed that allows the window wall glazing system or curtain wall glazing system to perform whether the exterior cover is present or not. According to aspects illustrated herein, in one embodiment, a window wall glazing system or curtain wall glazing system includes at least two insulating glass units, at least two methods for fixing glass lites of the insulating glass units in place on both sides of a mullion (SSG or tape applied), and at least one rain screen gasket for providing a rain screen seal between the glass lites or panels against water/weather penetration. 
       FIGS. 1 and 2  show a weather seal  10  in accordance with an embodiment of the present disclosure. In one embodiment, the weather seal  10  is bilaterally symmetric with two portions  10 A and  10 B conjoined by a bridging web  12 . The web  12  serves to connect portions  10 A and  10 B and also to act as a weather seal. The length L of the weather seal  10  may approximate the length of the glazing panels between which it is inserted and may extend beyond a glazing panel to bridge the space between the next set of adjacent glazing panels, e.g., above and below the panels between which it is inserted. In one alternative, the weather seal  10  may be of a length L to extend the length of a plurality of glazing panels and/or may be cut to length at the time of use. 
     Each of portions  10 A and  10 B have a first wall  14 A,  14 B and a second wall  16 A,  16 B extending away from the web  12  and forming an H shaped cross-sectional shape. Short, angled flare walls  17 A,  17 B result in first end walls  18 A,  18 B being laterally, outwardly offset from first walls  14 A,  14 B to form a receiver  20 . Proximate the flare walls  17 A,  17 B, inwardly directed prominences  22 A,  22 B extend. The prominences  22 A,  22 B have sloped inner surfaces  24 A,  24 B that serve as guides to introduce a tongue  26  there between. The tongue  26  may be provided with a tip  28  having sloped surfaces  30 A,  30 B that encounter and slide over the prominences  22 A,  22 B in wedging fashion when the tongue  26  is inserted into the receiver  20 . The weather seal  10  may be formed from an elastic polymer, such as polypropylene, TPV, santoprene, polyamide or PVC, which may be extruded to form the weather seal  10 . The elasticity of the weather seal  10  allows the receiver  20  is spread apart when the tip  28  of the tongue  26  is pressed past the prominences  22 A,  22 B. The tongue  26  has recesses  34 A,  34 B that receive the prominences  22 A,  22 B, allowing the receiver  20  to assume a relaxed position with interior flat surfaces  36 A,  36 B of the prominences  22 A,  22 B abutting flat surfaces  38 A,  38 B of the recesses  34 A,  34 B and locking the tongue  26  in the recess  34 A,  34 B. Inwardly directed guide beads  42 A,  42 B provide centering of the tongue  26  as it is introduced into and held in the receiver  20 . The guide beads  42 A,  42 B also provide a frictional interaction of predetermined magnitude between the tongue  26  and the weather seal  10  that aids in holding the weather seal  10  in position on the tongue, but that does not impede installation or repositioning of the weather seal  10 . 
     Each of the portions  10 A,  10 B have a sealing fin  46 A,  46 B extending outwardly therefrom at an intermediate position, e.g., proximate web  12 . As shown in  FIG. 3 , the sealing fins  46 A,  46 B create an inboard seal as a second line of defense for water penetration, e.g., by resiliently pressing against an inboard glazing panel member  98 A,  100 A when the weather seal  10  is inserted between glazing panels  98 ,  100 . The sealing fins  46 A,  46 B may have an arcuate cross-sectional shape to increase the flexibility thereof to allow for assembly and material tolerance. In one embodiment, the sealing fins may curve in the opposite direction. The weather seal  10  has a second receiver  50  distal to the receiver  20 , at the end of second walls  16 A,  16 B, that is defined by flared walls  52 A,  52 B and end walls  54 A,  54 B. The receiver  50  receives a cap tongue  60  that extends from a cap  108 , as shown in  FIG. 4 . As with the first receiver  20 , receiver  50  has a pair of inwardly directed prominences  62 A,  62 B that may be received in recesses  63 A,  63 B in the cap tongue  60 . Sloped surfaces  64 A,  64 B,  68 A,  68 B, flat surfaces  66 A,  66 B and flat surfaces  70 A,  70 B of tip  74  perform the same functions as explained above relative to sloped surfaces  24 A,  24 B,  30 A,  30 B, flat surfaces  36 A,  36 B and flat surfaces  38 A,  38 B of tip  28 . As with the receiver  20 , receiver  50  can deform to receive the tip  74  and then return to a relaxed position, gripping the tip  74  and preventing its withdrawal from the receiver  50 . 
     Portions  10 A,  10 B also feature sealing bulbs  80 A,  80 B that extend from the end walls  54 A,  54 B. The sealing bulbs  80 A,  80 B are generally oval in cross section. The oval shapes may be modified by substantially flat portions  82 A,  82 B that join end walls  54 A,  54 B at an acute interior angle A and an obtuse exterior angle B. In one embodiment, angles A and B may both be close to 90 degrees. The flat portions  82 A,  82 B have ends  84 A,  84 B that approach and optionally touch one another, leaving a split S and covering the receiver  50  when in a relaxed position. The oval shape of the sealing bulbs  80 A,  80 B may also be modified by narrowed interior portions  86 A,  86 B that ease entry of the sealing bulbs  80 A,  80 B into the gap between adjacent glazing panels  98 ,  100 . Bulging portions  88 A,  88 B insure the sealing bulbs  80 A,  80 B extend across and seal the gap between glazing panels  98 ,  100 . The sealing bulbs  80 A,  80 B may be closed, with ends  92 A,  92 B monolithically extending from the receiver  50  (at or proximate to the flare walls  52 A,  52 B), increasing the rigidity of the sealing bulbs  80 A,  80 B. Alternatively, the ends  92 A,  92 B may be formed independently of and abut against the flare walls  52 A,  52 B, decreasing the rigidity of the sealing bulbs  80 A,  80 B. 
       FIGS. 3 and 4  show a glazed structure  90  with structural members  92 ,  94 ,  96  and glazing panels  98 ,  100 . The glazing panels  98 ,  100  shown are of different thicknesses and are held to the structural members  92  (a vertical mullion with a composite construction),  94 ,  96  (horizontal mullions) by different means. In actual use, only one type of glazing panel and attachment approach would typically be used for a particular application.  FIGS. 3 and 4  illustrate, however, that the weather seal  10  may be used in a range of applications. Glazing panel  98  is adhered to the structural members  92 ,  94 ,  96  by structural silicone glazing (SSG) techniques and materials, which are known in the art and are indicated by the silicone seal  98 S. Glazing panel  100  is adhered to the structural members  92 ,  94 ,  96  by structural tape glazing techniques and materials, which are also known in the art and are indicated by the structural tape  100 T. The weather seal  10  is inserted between the adjacent glazing panels  98 ,  100  after they are attached to the structural members  92 ,  94 ,  96 , spanning the gap there between and reducing or excluding weather infiltration in the form of precipitation and ambient air and radiation. As noted above, weather seal  10  locks on the tongue  26  extending from the structural member  92 . The weather seal  10  may be used to seal horizontal gaps between adjacent glazing panels like  98 ,  100  in a manner similar to the sealing of a vertical gap, as shown. An alternative position for a sealing fin  46 A′ may be employed to allow the fin  46 A′ to seal against another portion of the glazing panel  100  (e.g., the inner glass  100 A). As a further alternative, the weather seal  10  may be provided with a plurality of sealing fins  46 A,  46 B, e.g., two or three on each side, to be able to adapt to a variety of applications. As shown in  FIG. 3 , the flat surfaces  82 A,  82 B of the sealing bulbs  80 A,  80 B define a shallow V shape with a split S at the bottom of the V. The shallow V shape induces an approaching cap tongue  60  ( FIG. 2 ,  FIG. 4 ) to move toward and through the split S and into alignment with the receiver  50 . 
       FIG. 4  shows a cap  108 , e.g., made from a metal, such as an aluminum alloy. In one alternative, the cap  108  may be made from one or a combination of an aluminum alloy and a polymer, such as polypropylene, TPV, santoprene, polyamide or PVC. In one embodiment, the cap  108  may be produced by extrusion and has a generally rectangular cross-section. Strengthening ribs  110  may be used to increase rigidity. A cap tongue  60  with a tip  74 , recesses  63 A,  63 B ( FIG. 2 ) and lower portion  60 L extends from a front wall  120  of the cap  108 . As described in reference to  FIG. 2 , the tip  74  may be inserted into the second receiver  50  and interlock with the weather seal  10  preventing withdrawal therefrom. The weather seal  10  provides a sealing function as well as a cap  108  installation and retention function. The lower portion  60 L extends through the slit S, pushing the sealing bulbs  80 A,  80 B into closer engagement with the glazing panels  98 ,  100 . The cap may include gaskets  124 A,  124 B that intermediate between the cap  108  and the glazing panels  98 ,  100 , as well as providing an additional weather seal. 
     A weather seal  10  is disclosed herein which incorporates the benefits of a preformed gasket used in SSG conditions along with cap attachment features. The attachment features are concealed behind the exterior surface of the weather seal  10 . This dual functionality provides a single seal system that can optionally be used to achieve the aesthetic and functional effects of either a flush SSG system or a captured system. The weather seal  10  allows for positive engagement of the cap  108  by splitting along the face of the weather seal  10  during attachment of the cap  108 , which then snaps into place in the receiver  50 . The positive engagement of the cap  108  with the weather seal  10  eliminates the structural silicone seal otherwise needed to affix the cap  108  to adjacent glazing panels. The weather seal  10  assures accurate alignment and positioning relative to the glazing panels  98 ,  100 . 
     It will be understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the claimed subject matter. For example, while the receivers  20 ,  50  are shown as female coupling devices that receive a male tongue  26 ,  60  extending from the structure  92  and the cap  108 , this relationship could be reversed in one or both instances. For example, the tongue  26  could have a slot therein into which a male tongue extending from the weather seal  10  is inserted and snap-locked into place. Similarly, the weather seal could have a second male tongue that inserts into a slot formed in the cap  108  at the position where the male tongue  60  is situated in the illustrated embodiments. All such variations and modifications are intended to be included within the scope of the appended claims.