Abstract:
A support bracket for supporting a horizontal mullion during the construction of a curtain wall, the support bracket having a first horizontal leg and a second vertical leg in 90 degree relationship to each other, the horizontal leg defined by a support member engagable with the vertical mullion, the horizontal leg defined by a support member engagable with the horizontal mullion, there being a bracing member angularly secured between the vertical leg and the horizontal leg, the vertical and horizontal legs snap fitting or clamped to the respective horizontal mullion and vertical mullion to maintain the horizontal mullion in non-sagging relationship until it can be secured at its second end.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to curtain walls which are typically constructed with horizontal and vertical support members formed out of extruded aluminum and are erected in order to support glass panels or other panel material between the intersecting horizontal and vertical support members, the present invention relating to a support bracket used in the installation of the horizontal support members.  
         [0003]     2. Description of the Prior Art  
         [0004]     Curtain walls are widely used in the construction industry. They may be used to support glass panels or possibly decorative panels. A curtain wall can be one story high or several stories high. Typically the curtain wall is constructed with a plurality of vertical support members and interconnecting horizontal support members. The support members are typically made out of extruded aluminum and have a baked on aesthetic finish or an anodized metallic finish.  
         [0005]     In the trade, the vertical support member is typically referred to as a vertical mullion and the horizontal support member is referred to as a horizontal mullion. In one installation method, commonly known as the “Stick” method, in which all verticals and horizontals are sent to the job site (knocked down), a first vertical mullion is positioned and secured. On its lateral faces there will be installed, or will have been installed, a plurality of shear blocks consisting of an extruded aluminum block which is secured to the lateral face or faces of the vertical mullion, the cross section of the vertical shear block conforming to the internal cross section of a horizontal mullion. A first end of a horizontal mullion is then secured to the shear block. Depending upon the height of the curtain wall, there may be a plurality of horizontal mullions secured to a plurality of shear blocks at spaced apart distances. Once the first end of the horizontal mullions have been secured to their respective shear blocks, the second adjacent vertical mullion is positioned or secured with its own set of complimentary shear blocks to accommodate the second ends of the horizontal mullions. The installers must then match up the second end of the horizontal mullion with the appropriate shear block and secure same. Once all of the horizontal mullions between the two adjacent vertical mullions are secured, depending upon the width of the curtain wall, the installers will then secure a second set of horizontal mullions to the opposing face of the second vertical mullion and proceed as described until the entire width of the curtain wall is installed.  
         [0006]     The difficulty with this procedure arises when the horizontal mullions are of a length which causes the horizontal mullion to sag and place excessive load or stress on the shear block before it can be connected to the second shear block. Horizontal mullions of relatively short distance do not weigh enough to cause the sag, but a horizontal mullion of any significant distance (3 ft or more) causes sag which misaligns the first end of the mullion which is already secured to a shear block and makes it difficult to align the second end of the horizontal mullion to the second shear block. This requires additional work on the part of the installers and oftentimes requires additional man power since you must have someone hold the end of the horizontal mullion so that it does not sag until it can be secured to the second shear block.  
         [0007]     In one version of curtain walls, particularly multi-story curtain walls, both the vertical mullion and the horizontal mullion are formed with a complimentary nose portion on the same side of the mullion such that when the complete curtain wall is erected, the intersecting nose portions define a spacial area for the receipt of glass or decorative panels. In another version of a curtain wall, only the horizontal mullion is formed with a nose portion and the vertical mullion has no nose portion. In still another version of a curtain wall used primarily for store fronts and the like where the height is not that great, the horizontal and vertical mullions are formed with no nose portions and the glass or decorative panel is supported on the upper surface of the horizontal mullion and secured to the vertical mullion by a clip means.  
         [0008]     Due to the substantial uniformity in the fabrication of vertical and horizontal mullions and curtain walls, Applicant has developed a support bracket which is easily used in the positioning of horizontal mullions and the support of the horizontal mullion until the second end of the horizontal mullion can be secured to its respective shear block.  
       OBJECTS OF THE INVENTION  
       [0009]     An object of the present invention is to provide for a novel support bracket for support of a horizontal mullion in the erection of a curtain wall to prevent sagging and aid in alignment of the horizontal connections during installation.  
         [0010]     Another object of the present invention is to provide for a novel support bracket for a horizontal mullion of a curtain wall which provides support until the horizontal mullion can be secured at both ends.  
         [0011]     An object of the present invention is to provide for a novel support bracket which snap fits or clamps into position to support a horizontal mullion during installation of a curtain wall.  
         [0012]     A still further object of the present invention is to provide for a novel support bracket which is reversible and can support a horizontal mullion from either the right end or left end during the construction of a curtain wall.  
       SUMMARY OF THE INVENTION  
       [0013]     A support bracket for supporting a horizontal mullion during the construction of a curtain wall, the support bracket having a first horizontal leg and a second vertical leg in 90 degree relationship to each other, the horizontal leg defined by a support member engagable with the vertical mullion, the horizontal leg defined by a support member engagable with the horizontal mullion, there being a bracing member angularly secured between the vertical leg and the horizontal leg, the vertical and horizontal legs snap fitting or clamped to the respective horizontal mullion and vertical mullion to maintain the horizontal mullion in non-sagging relationship until it can be secured at its second end. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     These and other objects of the present invention will become apparent, particularly when taken in light of the following illustrations wherein:  
         [0015]      FIG. 1  is an exploded front view of a typical installation of a horizontal mullion and a vertical mullion in the erection of a curtain wall wherein said mullions are formed with a nose portion;  
         [0016]      FIG. 2  is a cross sectional view of a vertical or horizontal mullion of  FIG. 1 ;  
         [0017]      FIG. 3  is a perspective view of a first embodiment of the support bracket of the present invention for mullions of  FIG. 1 ;  
         [0018]      FIG. 4  is a front view of the support bracket embodiment of  FIG. 3 ;  
         [0019]      FIG. 5  is a front view of the intersection of a horizontal mullion and vertical mullion of  FIG. 1  with the support bracket of the present invention positioned to support the horizontal mullion until its second end can be secured;  
         [0020]      FIG. 6  is a perspective view of a second embodiment of the support bracket of the present invention;  
         [0021]      FIG. 7  is a perspective view of another embodiment of the support bracket of the present invention for use in curtain wall installation when only the horizontal mullion is formed with a nose portion; and  
         [0022]      FIG. 8  is a perspective view of a support bracket for curtain wall installation of one or two story height in which neither the horizontal mullion nor the vertical mullion is formed with a nose portion. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0023]      FIGS. 1 through 6  illustrate a support bracket for erection of a curtain wall in which the vertical and horizontal mullions are formed with complimentary nose portions.  
         [0024]      FIG. 1  is an exploded front view of a typical installation of a horizontal mullion  10  and a vertical mullion  12  and  12 A in the erection of a curtain wall. Both mullions are fabricated from extruded aluminum and are generally rectangular in cross section defining a rectangular tubular inner portion  14  (See  FIG. 2 ). On one surface of the mullion there is formed integral therewith a nose portion  16  which protrudes from the wall and when the curtain wall is fully constructed serves as the periphery in which a glass panel or a architectural panel would rest and be secured by means of a cover, pressure plate, and fastener (not shown). Certain curtain walls are erected of horizontal and vertical mullions having no nose portion or only a horizontal nose portion. The support bracket of the present invention is modified in accordance with  FIGS. 7 and 8  to address these embodiments.  
         [0025]     Positioned in spaced apart relationship along one or more lateral sides of the vertical mullion are shear blocks  20 , the cross section of the shear block  20  conforming to the inner cross section  14  of the horizontal mullion. The shear block is secured to the vertical mullion by threaded fasteners  22  or other suitable fastening means. A first end  11  of a horizontal mullion  10  is then inserted over the shear block and threaded fasteners  24  or other suitable fastening means are utilized to secure the horizontal mullion to the shear block.  
         [0026]     Typically, vertical mullion  12  is positioned and secured with the shear blocks  20  in their respective positions. The installers then insert a horizontal mullion  10  over each of the shear blocks  20  and secure it with a threaded fastener  24 . The installers would then move to the location for the next adjacent vertical mullion  12 A and position it in place and secure the opposing end  13  of the horizontal mullion  10  to a respective shear block  20 A mounted on that adjacent vertical mullion  12 A. The opposing end  13  of the horizontal mullion  10  would then be secured to the respective shear block  20 A. Depending upon the size of the curtain wall, there may be a plurality of horizontal mullions  10  positioned between adjacent vertical mullions  12  and there may be a plurality of vertical mullions  12  spanning the distance for the curtain wall.  
         [0027]     If the horizontal mullion  10  is of a short enough span, no undo sheer force occurs where the first end  11  of a horizontal mullion  10  is secured to shear block  20 . However, if the horizontal mullion  10  is of a sufficient span, sufficient shear force is exerted on the shear block  20  prior to the second end  13  of the horizontal mullion being secured to the next adjacent vertical mullion  12 A that the horizontal mullion can sag and come out of square. When this problem arises, the installer often requires an additional individual to support the second end  13  of a horizontal mullion  10  until it can be secured. This increases the labor cost of erecting the curtain wall. Still further, if the sheer force is sufficient enough, the first end  11  of the horizontal mullion  10  is pulled away from the vertical mullions creating spaces at joints and requiring additional installation time to correct the aesthetics of the installation.  
         [0028]      FIG. 3  is a perspective view of a first embodiment of Applicant&#39;s installation bracket and  FIG. 4  is a front view. In this design, the bracket  40  is L-shaped in configuration having a horizontal leg  42  and a vertical leg  44  in fixed 90 degree relationship. Horizontal leg  42  is formed of a U-shaped extruded aluminum member, forming a longitudinal channel  46  defined by its side walls  48 ,  50  and end wall  52  dimensioned such that it can be slid or fitted over the nose portion  16  of a horizontal mullion  10 . The vertical leg  44  is comprised of a U-shaped extruded aluminum member which again defines a longitudinal channel  54  defined by side walls  56 ,  58 , and end wall  60 , which can be slipped or snap fit over the nose portion of a vertical mullion.  
         [0029]     In this configuration (See  FIG. 5 ), when the first end  11  of a horizontal mullion  10  has been secured to the shear block  20  on a vertical mullion  12 , the installer snap fits the installation bracket  40  such that the vertical leg  44  snaps over the nose portion  16  of the vertical mullion  12  and the horizontal leg member  42  snaps over the nose portion  16  of the horizontal mullion  10 , thereby providing additional support for the horizontal mullion  10  until the second end  13  can be secured to the shear block  20 A of the adjacent vertical mullion  12 A. For added support, an angled bracing member  62  is attached to the horizontal and vertical leg  42  and  44  at an angle. In this first embodiment, the horizontal leg and the vertical leg are formed of U-shaped extruded aluminum members having a channel on one side. In a second embodiment (See  FIG. 6 ), the installation bracket  40 A may be fabricated of extruded aluminum members having I-beam-like cross section such that there is a channel  46 A and  46 B and  54 A and  54 B defined on both sides of the horizontal and vertical leg  42 A and  42 B respectively. In this configuration, the installation bracket can be easily adapted to either a right hand or a left hand installation of a horizontal mullion to a vertical mullion. In either embodiment the respective U-shaped channels engage the nose portion of the mullion. In some instances the snap fit relationship is sufficient to maintain the bracket and horizontal mullion in position, however in some instances it is necessary to utilize a C-clamp or similar temporary securing device between the bracket and the mullion.  
         [0030]      FIG. 7  is a perspective view of another embodiment of a support bracket for the erection of a curtain wall in which only the horizontal mullion is formed with a nose portion. The basic support bracket  70  is identical to the support bracket illustrated in  FIG. 6  and utilizes the same respective reference numerals. The channel  46 A would engage the nose portion of the horizontal mullion. Since the vertical mullion would have no nose portion, the bracket is adapted by securing a vertical plate member  72  to the vertical portion of the support bracket. In this configuration, vertical plate  72  is positioned in abutting relationship to the outside surface of the vertical mullion and the channel  46 A can engage the horizontal nose piece. The bracket is maintained in position by a clamp means such as a C-clamp or the like between the vertical plate  72  and the abutting vertical mullion.  
         [0031]      FIG. 8  illustrates the support bracket of the present invention adapted for the installation and erection of a curtain wall of the one story or two story variety in which neither the vertical mullion or the horizontal mullion is formed with a nose portion. The bracket  80  illustrated in  FIG. 8  is similar in all respects with respect to the bracket  70  illustrated in  FIG. 7  with the exception that an additional horizontal plate is now secured to the horizontal member of the support bracket. Additional horizontal plate  82  is secured to the horizontal portion of the support bracket. In this configuration, the vertical plate  72  is placed in abutting relationship with the outside surface of the vertical mullion. The horizontal mullion is secured to its shear block as described heretofore, and the horizontal plate  82  is clamped to the horizontal mullion abutting its underside surface. Once the horizontal mullion has been secured at its second end as described heretofore, the clamps securing the horizontal plate  82  to the underside of horizontal mullion and the clamp securing the vertical plate  72  to the outer side of the vertical mullion are removed and the bracket is removed for further use on additional mullion installations.  
         [0032]     While the present invention has been described with respect to the exemplary embodiments thereof, it will be recognized by those of ordinary skill in the art that many modifications or changes can be achieved without departing from the spirit and scope of the invention. Therefore it is manifestly intended that the invention be limited only by the scope of the claims and the equivalence thereof.