Patent Publication Number: US-2006016137-A1

Title: System for joining mullions to transoms by frontal link

Description:
APPLICATION FIELD  
      This patent refers to a system for joining section bars used in facades (both to mullions and transoms, be they structural or semi-structural) band frames, movable walls and in general wherever mullions are to be joined to transoms with mitred joints, without additional work.  
     STATE OF THE ART  
      A great number of systems for joining mullions to transoms by means of metal or plastic section bars are available. The most advanced systems provide for non-sequential joining of section bars by frontal Insertion of transoms into mullions. This allows transom preparation before assembly, with a subsequent reduction in costs. Costs are further decreased also because this particular method enables an easier assembly process compared to that of sequential joining systems.  
      Unfortunately, the frontal joining systems known today, although effective, have relatively high assembly and disassembly costs. In order to decrease these costs many new solutions have been devised, with the aim of reducing preparation of the parts to be linked to the minimum.  
      We have thus passed from the preparation of mullions—to create notches where transoms are to be inserted—to the adjustment of the transoms themselves. The latter, after having been cut to the desired length, are milled or sheared in order to remove a portion of their outer wall, close to the ends.  
      The transoms are then frontally inserted into side supports which have been fastened to the mullions by means of screws and are tightly locked to them with additional screws. Additionally, in order to favour the discharge of condensation water through the mullion&#39;s gutter, transom ends are milled once again, so as to obtain two projections, one on each side, directing the water into the above mentioned channel.  
      It is clear that mullion and transom preparation costs are very high, given the number of adjustments to be performed: double milling or shearing of transoms, milling of mullions, double perforation of mullions (in order to create the holes in which both the screws for the side supports and those needed for joining the transoms to the mullions will be fastened).  
      Moreover, a certain amount of labour is required both for the preparation of the section bars and the fastening of side supports in advance.  
      Alternative frontal fastening methods include the use of linking elements which make it possible to skip part of the section bar preparation process.  
      According to these new methods, transoms are cut to the desired length. The ends are then closed with plastic plugs which act both as gaskets and dilatation compensators. Finally, transoms and mullions are joined together with metal bars which are placed horizontally between the two and fastened to them by means of screws. The metal bars are fitted into special transom channels or chambers, creating a typical cross-shaped joint where screws are essential to keep the structure tightly fastened. Apart from the transoms&#39; low resistance to torsion stress, it is however necessary to pierce or shear both the mullions and the transoms, which makes preparation of the various parts expensive, although to a lesser extent.  
     SUMMARY OF THE INVENTION  
      The aim of this invention is to offer users a section bar linking system which does not require extra adjustments other than the cutting of mullions and transoms during the making of facades, band frames and movable walls.  
      Consequently, this invention also aims at enabling frontal assembly and disassembly of section bars at extremely low costs, thus offering great economic advantages.  
      These and other aims are achieved by the system which is the subject matter of this invention and which is characterised by the use of section bars, an insert and spacers.  
      The section bars used for the making of transoms are provided with at least one channel (whose longitudinal axis is parallel to that of the section bars), developing vertically.  
      The section bars used for the making of mullions are provided with at least two grooves whose longitudinal axis is parallel to that of the section bars and symmetrical to the central beams. In its cross-section each groove is provided with at least one coupling jaw, one holding jaw, and one inclined plane. Each groove can be divided into two channels by a sufficiently flexible fin, whose longitudinal axis is parallel to that of the mullion, which has to be provided with at least one coupling and one holding jaw. At the end of at least one channel, a projection creates the inclined plane, while at the end of the other channel a projection creates a housing.  
      The insert is provided with at least one connection beam perpendicular to its body. The body of each insert is housed in at least one of the transom channels whereas the end supplied with the connection beam inevitably protrudes from the channel itself. The connection beam may vary in shape but in all cases has to be provided with at least one coupling and one holding jaw. The connection beam&#39;s end can be formed by a terminal, complementary or not to the above mentioned housing. The insert may also be supplied with a guide beam placed perpendicularly to the insert&#39;s body and in the same direction as the connection beam. This guide beam may be provided with a terminal, preferably placed at its distal end and perpendicularly to the beam. The insert body may be subdivided into two or more sections which are parallel to the transoms, joining at the mullion. The insert is provided with two or more holes, threaded or not, at least one of which is to be located on the insert&#39;s body itself and another near the connection beam. These holes hold screws or dowels.  
      Fitted into the holes, the screws and dowels prevent the insert from moving vertically. Nevertheless, in order to prevent heavy glass panes or panels or minute loads from causing a downward slip of the transom, a metal profile spacer may be used, having a varied section structure.  
      The spacer, which may host the vertical sealing gasket and act as a support for the shutters&#39; retaining elements, is fixed to the mullion by means of joints, gaskets or any other simple fitting method. It may have diverse shapes and may or may not be provided with a coupling jaw to be inserted in at least one of the mullion&#39;s jaws. The spacer is inserted into a specific slot for fitting or in at least one of the channels.  
      Each transom end may be closed by a tight plug, formed by a body having the same profile as the transom, with a support protruding from it and facing oppositely to the transom end. The support is provided with one or more slits whose clear span is the same size as that of the insert&#39;s body and may also be provided with horizontal holes.  
      By using the above described insert for the fixing of transoms to mullions, apart from transom cutting, all other adjustments are avoided. Transoms are previously cut to the desired length in the workshop and, if required, their ends are covered with the plugs in which the inserts are placed. Consequently, the persons in charge of assembling facades, band frames, movable walls etc., will simply have to fix the inserts to the mullions and the transoms. Assembly therefore becomes quick and easy, drastically reducing the costs and time usually required to carry out these operations. 
    
    
     SHORT DESCRIPTION OF DRAWINGS  
      Further characteristics and advantages of the present invention will be clearer from the description of some preferred, but not unique, embodiments of the invention showing—for information only, and without any limitation—the details of the system on the drawings enclosed herewith, where:  
       FIG. 1  shows the cross section of a mullion according to the invention;  
       FIG. 2  shows the cross section of a transom;  
       FIG. 3  shows the enlarged cross section of a spacer;  
       FIG. 4  shows an insert seen from above;  
       FIG. 5  shows an enlarged cross section of a mullion&#39;s seat;  
       FIG. 6  shows an enlarged longitudinal section of the extremity of the insert shown in  FIG. 4 ;  
       FIG. 7  shows a section of part of the area where the mullion and insert are joined;  
       FIG. 8  shows the transom, insert and plug seen from above;  
       FIG. 9  shows the exploded perspective view of the transom, the insert and plug previously illustrated;  
       FIG. 10  shows the same details described in the previous drawing, assembled together;  
       FIG. 11  shows the exploded perspective view of the mullion, transom, insert and plug illustrated in the previous drawings; part of the mullion has been removed in order to better show how the insert is locked into the mullion;  
       FIG. 12  shows the cross section of a second mullion according to the invention;  
       FIG. 13  shows the cross section of a second transom;  
       FIG. 14  shows an enlarged cross section of a second spacer;  
       FIG. 15  shows an enlarged cross section of part of the mullion shown in  FIG. 12 ;  
       FIG. 16  shows and enlarged view of a second insert, seen from above;  
       FIG. 17  shows a section of the mullion, transom, insert, plug and spacer shown in  FIGS. 12, 13 ,  14 , now joined together;  
       FIG. 18  shows another cross section of the transom shown in  FIG. 13 ;  
       FIG. 19  shows the exploded perspective view of the mullion, transom, insert and plug shown in  FIGS. 12-18 ;  
       FIG. 20  shows a cross section of a third mullion according to the invention;  
       FIG. 21  shows the cross section of a third transom;  
       FIG. 22  shows the cross section of a third spacer;  
       FIG. 23  shows the cross section of a fourth spacer;  
       FIG. 24  shows the enlarged cross section of part of the mullion shown in  FIG. 20 ;  
       FIG. 25  shows the enlarged view of a third insert, seen from above;  
       FIG. 26  shows a section of the mullion, transom, insert, plug and the two spacers shown in  FIGS. 20-25 , joined together;  
       FIG. 27  shows another cross section of the transom shown in  FIG. 21 ;  
       FIG. 28  shows the cross section of a mullion and a spacer for internal walls;  
       FIG. 29  shows the longitudinal section of a fourth insert;  
       FIG. 30  shows the cross section of the spacer shown in  FIG. 28 ;  
       FIG. 31  shows the cross section of a transom and its corresponding insert for internal walls. 
    
    
     DETAILED DESCRIPTION OF FOUR PREFERENTIAL METHODS OF REALISATION  
      A first example of realisation of the joining system here described, particularly suitable for continuous faades, foresees the use of insert  1 , of a section bar which will create mullion  2 , of a second section bar creating transom  3  and of spacer  4 .  
      Insert  1  is formed by a body  1 . 1  and a connection beam  1 . 2  which is perpendicular to the body itself. Body  1 . 1  of insert  1  is divided into two parts which are parallel to transoms  3 , joined together near beam  1 . 2 . Connection beam  1 . 2  is provided with a coupling jaw  1 . 3  and a holding jaw  1 . 4 . Insert  1  is provided with four holes, two threaded holes  1 . 5  along body  1 . 1  and two non-threaded holes  1 . 6  near connection beam  1 . 2 .  
      The section bars used to create transoms  3  have a box-like body  3 . 1  and two channels  3 . 2  whose longitudinal axis is parallel to that of transoms  3 , developing vertically. The two parts of body  1 . 1  of insert  1  are fitted into channels  3 . 2 , whereas the extremity provided with connection beam  1 . 2  protrudes from channels  3 . 2 .  
      The section bars used to create mullions  2  have a box-like body  2 . 1  and a double seat  2 . 2 , whose longitudinal axis Is parallel to that of the section bars and rigid edges. The central beams  2 . 3  holding the section bar which blocks the glass or panel, are placed between the two seats  2 . 2 . On the side facing beams  2 . 3 , each seat  2 . 2  is closed by fin  2 . 4 , whose longitudinal axis is parallel to that of mullion  2 . Fin  2 . 4  is provided with a coupling jaw  2 . 5 . A holding jaw  2 . 6  is placed opposite to jaw  2 . 5  on the edge of seat  2 . 2  facing the external side of mullion  2 . At the bottom of each seat  2 . 2  a projection creates inclined plane  2 . 7 . The edge facing central beams  2 . 3  of seat  2 . 2  is also inclined, thus forming another inclined plane,  2 . 8 .  
      A third section bar is used both as an internal glass-holder and as a spacer,  4 . It Is formed by body  4 . 1  which is provided with two beams  4 . 2 . Each beam is provided with a coupling jaw,  4 . 3 .  
      A tight plug  5  closes the ends of each transom  3 . Each plug  5  is formed by a body  5 . 1  having the same profile as the tubular portion of transom  3  and a support  5 . 2  protruding from body  5 . 1  itself. Plug  5  is crossed by two vertical slits  5 . 3  having a clear span of the same size as the two parts of body  1 . 1  of insert  1  and by two horizontal holes  5 . 4 , if required.  
      At the time of assembly, transom  3 , already equipped with plugs  5  and inserts  1  at its extremities, is brought close to mullion  2 , frontally. Connection beam  1 . 2  of each insert  1  is fitted into each of seats  2 . 2  until coupling jaw  1 . 3  clasps to coupling jaw  2 . 5 . The coupling of jaws  1 . 3  and  2 . 5  avoids that the group formed by transom  3  and insert  1  should detach from mullion  2 . In order to lock insert  1  and prevent the group formed by insert  1  and transom  2  from sliding vertically along mullion  2 , screws  6  are inserted in holes  1 . 6  placed close to connection beam  1 . 2 . These screws, which may also pass through holes  5 . 4  of plug  5 , engrave jaw  2 . 6 , creating horizontal grooves which prevent the above mentioned vertical sliding. By inserting screws  6  into seat  2 . 2 , connection beam  1 . 2  of each insert  1  is pushed against its corresponding inclined plane  2 . 8 . At the same time, the Ups of screws  6  use the second inclined plane  2 . 7  as a fulcrum to lever on plug  5 , forcing it to press against mullion  2 , thus preventing water leakage and therefore ensuring a tight system. Two dowels  7  prevent insert  1  from moving within channels  3 . 2  of transom  3 . Dowels  7  are inserted in threaded holes  1 . 5  of body  1 . 1  of insert  1  engraving the walls of transom  3 .  
      Spacer  4 , formed by a glass-holding section bar, prevents insert  1  from moving vertically when transom  3  has to support heavy or sudden loads.  
      Both beams  4 . 2  are inserted in the same seat  2 . 2  of mullion  2  in which beam  1 . 2  of insert  1  is housed. Jaws  4 . 3  couple with coupling jaw  2 . 5  and holding jaw  2 . 6  of seat  2 . 2  thus tightly fastening spacer  4  to mullion  2 .  
      Spacer  4  is placed between one insert  1  and the insert above it. Its function is not only that of holding the glass, it also creates a vertical distance between one transom  3  and the other and supports them. Assembly time is therefore reduced since scribing on mullions  2  is no longer necessary.  
      Assembly is sequential and upward oriented. After locking mullions  2  in the desired position, a first transom  3  is fastened to two contiguous mullions  2 ; then, spacers  4  are fitted into the two mullions  2  placed above the first two inserts  1 , then another transom  3  is fastened and the sequence continues until the fagade is completed.  
      A second example of realisation of the joining system here described, also suitable for continuous fagades, still foresees the use of an insert  1 , of a section bar which will create mullion  2 , of a second section bar creating transom  3  and of a spacer  4 .  
      In this second example, apart from a coupling jaw  1 . 3  and a holding jaw  1 . 4  opposite to it, insert  1  is provided with a terminal  1 . 7 . Insert  1  is also provided with a guiding beam  1 . 8  placed perpendicularly to body  1 . 1  and facing the same direction as connection beam  1 . 2 . This second beam  1 . 8  is also provided with a terminal  1 . 9 , placed at Its distal extremity and perpendicular to beam  1 . 8  itself.  
      The section bars used to create mullions  2  have each double seat  2 . 2  divided into two channels  2 . 9  and  2 . 10 , and by fin  2 . 4 , which in this case is thin and flexible. Coupling jaw  2 . 5  and holding jaw  2 . 6  are placed on fin  2 . 4  itself; coupling jaw  2 . 5  facing channel  2 . 9  and holding jaw  2 . 6  facing channel  2 . 10 . At the bottom of channel  2 . 10 , placed towards the middle of mullion  2 , a projection creates inclined plane  2 . 7 . At the bottom of channel  2 . 9 , placed towards the external side of mullion  2 , a projection  2 . 11 , together with the walls of channel  2 . 9 , creates housing  2 . 12 .  
      The section bar used as spacer  4 , is formed by a body  4 . 1  and two beams  4 . 2  One of the two beams is provided with a coupling jaw  4 . 3  while the other beam ends with a fin  4 . 4  placed perpendicularly to the beam  4 . 2  itself. Housing  4 . 5  of body  4 . 1  holds a vertical gasket  8 .  
      At the time of assembly, transom  3 , already equipped with plugs  5  and inserts  1  at its extremities, is frontally brought close to mullion  2 . Connection beam  1 . 2  of each insert  1  is fitted into the most external channel  2 . 9  and guiding beam  1 . 8  into the second channel  2 . 10  until coupling jaw  1 . 3  clasps to coupling jaw  2 . 5 . The encumbrance of beam  1 . 2  determines its correct coupling with mullion  2 . In fact, it has to be greater than the distance between the lateral extremity of jaw  2 . 5  and the edge of channel  2 . 9  (net measure) thus forcing the fin to bend when connection beam  1 . 2  is inserted into channel  2 . 9 . When jaws  1 . 3  and  2 . 5  clasp together, fin  2 . 4  returns to its original position simultaneously pushing beam  1 . 2  against the edge of is channel  2 . 9  opposite to that of fin  2 . 4  and forcing the support area  1 . 4  of connection beam  1 . 2  against rigid edge  2 . 13 . Eventually, terminal  1 . 7  places itself into housing  2 . 12  placed between the edges of channel  2 . 9  and projection  2 . 11 .  
      The coupling of jaws  1 . 3  and  2 . 5  avoids that insert  1  should detach from mullion  2 . The contact between the support area  1 . 4  and the edge  2 . 13  of channel  2 . 9  and the contact between terminal  1 . 7  and the walls of housing  2 . 12  prevents insert  1 —and therefore transom  3 —from rotating along one of its longitudinal axes.  
      Screws  6 , which also pass through holes  5 . 4  of plug  5 , are inserted into holes  1 . 6  close to connection beam and engrave holding jaw  2 . 6 . Beam  1 . 8  guides screws  6  into channel  2 . 10 . The locking with screws  6  is therefore performed by using the more central channel  2 . 10  and not channel  2 . 9  where beam  1 . 2  is housed. By inserting screws  6 , fin  2 . 4  does not bend and its jaw  2 . 5  does not detach from jaw  1 . 3  of connection beam  1 . 2 .  
      Both beams  4 . 2  are inserted in the same channel  2 . 9  of mullion  2  in which beam  1 . 2  of insert  1  is housed. Jaw  4 . 3  couples with coupling jaw  2 . 5  of fin  2 . 4 . Fin  4 . 4  of the other beam  4 . 2  places itself in housing  2 . 12  thus tightly fastening spacer  4  to mullion  2 .  
      A third example of realisation of the joining system here described, also suitable for continuous facades, still foresees the use of an insert  1 , of a section bar which will create mullion  2 , of a second section bar creating transom  3  and of a spacer  9 . These details differ in shape but they have the same characteristics as the ones previously described.  
      The only variations are the absence of the two terminals  1 . 7  and  1 . 9 , the shape of spacer  9  and its housing onto mullion  2 . Spacer  9  is provided with two beams,  9 . 1  and  9 . 2 . Beam  9 . 2  is provided with a coupling jaw  9 . 3 . Beam  9 . 2  is fitted into the most peripheral channel  2 . 9  of mullion  2  and its coupling jaw  9 . 3  joins with coupling jaw  2 . 5  of channel  2 . 10 . The other beam  9 . 1  fits into the other channel  2 . 10 .  
      A second spacer may be used, spacer  10 , which has the double function of creating a distance between transoms  3  and supporting the elements which fasten the doors. It is provided with two beams,  10 . 1  and  10 . 2  which are fitted into yet another channel  2 . 14  of mullion  2  having a different position, lateral, and a different function compared to that of channels  2 . 9  and  2 . 10  which serve to lock both insert  1  and spacer  9 . Spacer  10  is fastened to mullion  2  by means of gasket  11  which is provided with a relief  11 . 1  intended to occupy groove  2 . 15  within channel  2 . 14 .  
      A fourth example of realisation of the joining system here described, particularly suitable for interior movable walls, uses an insert  1 , a section bar suitable to create mullion  2 , of a second section bar creating transom  3  and of a spacer  12 . Also in this case the details differ in shape but they have the same characteristics as the ones previously described. Fin  2 . 4  of mullion  2  is not provided with the inclined plane  2 . 7 , the transom is only provided with one channel  3 . 2  and spacer  12  has two beams,  12 . 1  and  12 . 2 , one of which is provided with a coupling jaw  9 . 3 . Beam  12 . 2  of spacer  12  externally embraces mullion  2 . Coupling jaw  12 . 3  of beam  12 . 1  of spacer  12  joins with holding jaw  2 . 6  of channel  2 . 10 .  
      When fixing insert  1 , two dowels  13  are used to prevent insert  1 —and thereafter transom  3 —from moving vertically. These dowels are inserted in holes  1 . 6  placed close to connection beam  1 . 2  where they engrave jaw  2 . 6  of fin  2 . 4 . The fitting of the dowels  13  ends when their tips come into contact with terminal  1 . 9  of guide beam  1 . 8 , thus creating an end-stop. In this case the inclined plane  2 . 7  is not foreseen. In fact, since the tightness of the internal walls is not necessary, no plugs are used and the fulcrum function previously described for inclined plane  2 . 7  is senseless.