Patent Description:
The invention pertains to a curtain wall system comprising mullions or transoms that include a thermally insulating component. The insulating component is a fiberglass reinforced polymer that is bonded to a metal structure. The metal structure may be made of steel or aluminum for instance. The bonding can be accomplished using adhesives and/or other bonding techniques and produces a mullion or transom having sufficient strength to support the panels or glazing of the curtain wall. The thermally insulating fiberglass component enhances the insulating properties of the mullions, transoms and curtain wall system.

<CIT> describes a curtain wall system in which a thermally insulating component is fitted to a mullion or transom structure.

According to the invention there is provided a curtain wall mullion or transom for use in a curtain wall system as defined by appended Claim <NUM>. The invention also relates to a method of manufacture thereof as defined by appended Claim <NUM>.

The metal curtain wall mullion or transom has an outer side and a component connected to the outer side by a first fastener passing through the outer side and into the component. The fastener is inserted from the inside-out, i.e., from the inside of the metal structure, through the outer side, and into the component.

Also described herein is a steel mullion or transom that can include a stem projecting from the mullion or transom where the stem can be configured to project into a space between a first panel and a second panel of a curtain wall. Since the stem is made of thermally insulating material the structure provides enhanced overall insulating properties of a resultant curtain wall system.

Also described herein is a mullion or transom for use on a curtain wall system having at least one panel which can comprise a metal structural segment and a component made of thermally insulating material and bonded to the metal segment. The component can include a seal receiver configured to receive a seal to be positioned between the metal segment and the panel.

Also described herein is a curtain wall system that can include a cell having a first mullion, a second mullion, a first transom and a second transom. The first transom can include a metal structure having a fiberglass component bonded to the metal structure, and a panel secured to the cell. The fiberglass component can include a stem configured to support a weight of the panel.

Also described herein is a method of making a component by pultruding a fiberglass to have a profile configured to cover an entirety of an outside of a mullion or transom of a curtain wall and to have a pair of receivers for receiving seals to abut against panels of the curtain wall. Further profiles are contemplated under the methods of making components by pultrusion.

The above partial summary of the present invention is not intended to describe each illustrated embodiment, aspect, or every implementation of the present invention. The figures and detailed description and claims that follow more particularly exemplify these and other embodiments and further aspects of the invention.

The invention may be more completely understood in consideration of the following description of various embodiments of the invention in connection with the accompanying drawings, in which:.

<FIG> are described for a better understanding of the invention. While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not necessarily to limit the invention to the particular embodiments, aspects and features described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention and as defined by the appended claims.

<FIG> is a front view of a cell <NUM> of a curtain wall system <NUM>. System <NUM> is shown in partial (and panels are not shown). It may be appreciated that multiple cells <NUM> may comprise system <NUM>. <FIG> is a sectional view of a mullion <NUM> of cell <NUM>. <FIG> is a sectional view of a transom <NUM> of cell <NUM>. A similar transom <NUM>' is positioned generally parallel with transom <NUM>. A similar mullion <NUM>' is positioned generally parallel with mullion <NUM>. Together mullions <NUM>, <NUM>' and transoms <NUM>, <NUM>' comprise a single cell <NUM> of curtain wall system <NUM>. It may be appreciated that mullions <NUM> and transoms <NUM> also comprise additional cells <NUM>' or components of cells <NUM>' of system <NUM>. It may be appreciated that panels such as windows, glass, or plates or other objects may be inserted within a cell <NUM> to cover or span the space, light or opening created by mullions <NUM> and transoms <NUM>.

As shown in <FIG>, mullion <NUM> includes a first mullion segment <NUM>. In some embodiments mullion <NUM> includes a second mullion segment <NUM> and a third mullion segment <NUM>. Mullion segments <NUM>, <NUM> and <NUM> form a mullion <NUM> and define a mullion cavity <NUM>. In some embodiments mullion <NUM> is made of steel. Particularly, segments <NUM>, <NUM> and <NUM> may be made of steel. In one example, segments <NUM>, <NUM> and <NUM> may be formed by bending <NUM> gage steel sheets. In one example mullion <NUM> includes a polymer component <NUM> which is bonded to mullion <NUM>. Polymer component <NUM> is formed of a thermally insulating material. In one example polymer component <NUM> is made of fiberglass reinforced polymer (FRP) or glass-fiber reinforced polymer (GFRP) which in one example is a fiber reinforced polymer including plastic. A variety of glass, fiberglass and/or plastics may be used. In one example polymer component <NUM> is made of material including fiberglass and polyester, or fiberglass and vinyl ester, or fiberglass and polymers, and may include non-fire-retardant materials or fire-retardant materials. Polymer component <NUM> may be made using a pultrusion process and may include reinforcing structures or mats to provide structural support. Rovings may be located in the component <NUM> which may also include an external coating or coatings. Polymer component <NUM> thus has favorable insulating features. In one example involving steel structural segments <NUM>, <NUM> and <NUM>, polymer component <NUM> fills a gap that would otherwise lead from outer side <NUM> to cavity <NUM>.

In one example polymer component <NUM> is bonded to mullion <NUM> with an adhesive. A variety of bonding ingredients and techniques may be used to secure polymer component <NUM> to mullion <NUM>. As shown in one example, polymer component <NUM> includes an interlock <NUM> which is configured to receive tail <NUM> of first mullion segment <NUM>. Tail <NUM> may be both friction fit within interlock <NUM> and also bonded within interlock <NUM> with an adhesive and/or bonding treatments. In one example interlock <NUM> is a gap defined by polymer component <NUM>. Polymer component <NUM> may include a lip <NUM> which in part defines interlock <NUM> as shown. Polymer component <NUM> also includes a first arm <NUM> having a tail-contact surface <NUM> which is bonded to the outside surface of tail <NUM>. In one example, tail contact surface <NUM> covers the entire area of the outside surface of tail <NUM>. In this manner tail <NUM> is not exposed to the outside element which would otherwise tend to corrode or deteriorate tail <NUM>. Polymer component <NUM> also includes a second arm <NUM> having a tail contact surface <NUM> which in one example may be bonded to the outside surface of tail <NUM> of third mullion segment <NUM>. In one example tail contact surface <NUM> may cover the entirety of the outside surface of tail <NUM>. It may be appreciated that contact surface <NUM> may also cover less than the entirety of the outside surface of tail <NUM>. Polymer component <NUM> may also include a further lip <NUM> configured to adhere to tail <NUM>. In further examples arm <NUM> may loosely fit against tail <NUM> (i.e., not be bonded) so that arm <NUM> may slide with respect to tail <NUM>. Likewise, lip <NUM> may also be a loose fit against tail <NUM>. It may be appreciated that alternative configurations of polymer component <NUM> may be used to assist in adhering polymer component <NUM> to mullion <NUM> (whether adhering to segment <NUM>, <NUM> or <NUM>). Polymer component <NUM> is configured to adhere to mullion <NUM> while also having a stem portion <NUM> extending between or into a gap or pocket defined in part by panels <NUM>, <NUM>'. A fastener <NUM> may insert through a pressure plate <NUM> and into the stem to secure panels <NUM>, <NUM>' in position. Seals <NUM>, <NUM> may be positioned between pressure plate <NUM> and panel frame <NUM>. A cover plate <NUM> may be positioned to cover pressure plate <NUM>. It may be appreciated that panel <NUM> may be positioned within cell <NUM> while panel <NUM>' may be positioned within an adjacent cell <NUM>'.

In a further example polymer component <NUM> includes a seal receiver <NUM> configured to receive a seal <NUM>. In one example seal receiver is defined by seal fingers <NUM>. Seal <NUM> is configured to insert into seal receiver <NUM> and between first arm <NUM> and panel frame <NUM>. Seal <NUM> may fiction fit to panel frame <NUM> and may also be bonded to panel frame <NUM>. Seal <NUM> may be of a conventional variety used in curtain wall systems. Seal <NUM> may also include a wrap segment <NUM> to partially cover an edge of first arm <NUM>. In a further example polymer component <NUM> includes a further seal receiver <NUM> positioned at or defined by second arm <NUM>. In one example seal receiver <NUM> may be configured to receive a seal <NUM> configured to interact with a shoulder <NUM> described below. In one example seal <NUM> is positioned between second mullion segment <NUM> and third mullion segment <NUM>.

As shown in <FIG> mullion <NUM> includes a shoulder <NUM> connected to second mullion segment <NUM>. In one example shoulder <NUM> includes an interlock <NUM>'. Interlock <NUM>' is configured to receive tail <NUM> of segment <NUM>. Tail <NUM> may friction fit within interlock <NUM>' and/or be bonded to shoulder <NUM> within interlock <NUM>'. Shoulder <NUM> is made from the same or similar material as is polymer component <NUM> described above. In one example shoulder <NUM> abuts polymer component <NUM>. A sealant <NUM> may be applied where shoulder <NUM> meets polymer component <NUM>. In a further example shoulder <NUM> includes a seal receiver <NUM>'. Receiver <NUM>' is configured to receive a seal <NUM>. In one example seal receiver <NUM>' is defined by seal fingers <NUM>. Seal <NUM> is configured to insert into seal receiver <NUM>' and between shoulder <NUM> and panel frame <NUM>. Seal <NUM> may friction fit to panel frame <NUM>. Seal <NUM> may be of a conventional variety used in curtain wall systems. Panel frame <NUM> may also be secured to seal <NUM> with an adhesive. Seal <NUM> may also include a wrap segment <NUM> to partially cover an edge of shoulder <NUM>. In a further example shoulder <NUM> may be configured without elbow <NUM> (i.e., elbow extends from shoulder <NUM> at line "e" as shown in <FIG>). Tail <NUM> may extend further toward tail <NUM> to lessen a gap there between. Shoulder <NUM> may friction fit or interlock and/or bond to tail <NUM>.

It may be appreciated that polymer component <NUM> and shoulder <NUM> combine to cover the entirety of the outer side <NUM> of mullion <NUM>. Particularly, polymer component <NUM> and shoulder <NUM> are configured such that no portion of mullion <NUM> is exposed to outer side <NUM>, nor is any segment of mullion <NUM> in communication with the panels <NUM>, <NUM>' or the pocket <NUM> between panels <NUM>, <NUM>'. Maintaining the segments of mullion <NUM> in isolation from the outside atmosphere improves the insulating characteristics of system <NUM>.

As shown, mullion <NUM> is a composite structure made of steel segments <NUM>, <NUM>, <NUM> to which the fiberglass items, such as polymer component <NUM> and shoulder <NUM> are bonded or laminated. Polymer component <NUM> and shoulder <NUM> are configured to remain connected to mullion <NUM>. In one example polymer component <NUM> and shoulder <NUM> are continuous in that they span the length of mullion <NUM>.

As shown in <FIG>, transom <NUM> (i.e., a horizontally oriented element of cell <NUM>) includes polymer component <NUM> which is made of material that is the same or similar to the material used to make polymer component <NUM> referenced above. Polymer component <NUM> includes a first arm <NUM> having a transom contact surface <NUM> and a second arm <NUM> having a transom contact surface <NUM>. In one example component <NUM> is bonded to transom <NUM> at least at contact surfaces <NUM>, <NUM>. Particularly, first arm <NUM> and second arm <NUM> may be bonded with an adhesive and other bonding techniques to transom wall <NUM>. Wall <NUM> is formed of metal and in one example is formed of steel and in one example is bent into configuration.

As shown in <FIG>, wall <NUM> includes receiving arm <NUM>, <NUM>'. In one example arm <NUM> is integrally connected to wall <NUM> and is configured to receive contact surface <NUM>. Receiving arm <NUM> may be bent into position as shown for instance in <FIG> and then welded to transom plate <NUM> at weld <NUM>. In one example receiving arm <NUM> leads to receiving hand <NUM> and hand <NUM> is in turn welded to transom plate <NUM> with weld <NUM>. It may be appreciated that hand <NUM><NUM>' may be oriented parallel or at least substantially parallel with hand <NUM>. As such, hand <NUM> and hand <NUM>' are opposing walls. Polymer component <NUM> further includes fingers 141a, 141b configured to bond with wall <NUM>. In one example finger 141a is bonded to hand <NUM> and finger 141b is bonded to hand <NUM>'. An adhesive may be applied between polymer component <NUM> and wall <NUM> to securely bond component <NUM> along an entirety of the exterior surface of arm <NUM> and continuing about the curve <NUM> and along hand <NUM>. Likewise, an adhesive may be applied to securely bond component <NUM> along an entirety of the exterior surface of arm <NUM>' and continuing about the curve and along hand <NUM>'. It may be appreciated that the combination of adhesive and the structural matching arrangement of fingers <NUM> combine to provide a secure bond sufficient to allow component <NUM> to withstand the forces associated with bearing the weight of panels <NUM>, <NUM>' and other forces associated with or applied to the panels.

Fingers 141a, 141b also allow for efficient alignment of component <NUM> onto wall <NUM>. Fingers <NUM> are positioned on component <NUM> to match the gap between hands <NUM>, <NUM>' and to also receive an adhesive between component <NUM> and wall <NUM>. Wall <NUM> is bent with corners <NUM> to match the contour of finger 141a (and/or vice versa) and the same is presented with finger 141b and at a distance to match the gap between hands <NUM>, <NUM>', to provide a secure bond. A variety of steps for preparing the surfaces and/or curing or treating the adhesives, as needed, may be used to achieve a secure bond of component <NUM> to wall <NUM>. It may be appreciated that fingers <NUM> may be positioned in different locations, and in some applications may be reconfigured into different shapes/dimension and/or removed altogether.

It may be appreciated that polymer component <NUM> covers the entirety of outer side <NUM> of transom <NUM>. Such configuration assures that no portion of transom <NUM> is in communication with the exterior atmosphere or panels <NUM>, <NUM>' or the pocket <NUM> between panels <NUM>, <NUM>'. Maintaining such isolation improves the insulating characteristics of system <NUM>.

In a further example polymer component <NUM> includes a seal receiver <NUM>. Receiver <NUM> is configured to receive a gasket or seal <NUM>. In one example seal receiver is defined by seal fingers <NUM>. Seal <NUM> is configured to insert into seal receiver <NUM> and between component <NUM>, <NUM>, and panel frame <NUM>, i.e., between first arm <NUM> and panel frame <NUM>. Seal <NUM> may be bonded to panel frame <NUM>. Seal <NUM> may be of a conventional variety used in curtain wall systems.

In one example a pressure plate <NUM> is fastened with a screw <NUM> to stem <NUM> of component <NUM> and applies pressure to seals <NUM> which in turn apply pressure to panels <NUM>, <NUM>' and against component <NUM>. It may be appreciated that a setting block may be positioned between stem <NUM> and panel <NUM>. It may be appreciated that component <NUM> together with pressure plate <NUM> secure panels <NUM>, <NUM>' to transom <NUM>.

In a further example the stem <NUM> includes a groove <NUM> configured to receive a fastener <NUM> (see also <FIG>). Groove <NUM> may include a taper <NUM> to assist in receiving fastener <NUM>. Groove <NUM> may be a continuous groove which spans the length of component <NUM>, <NUM>. It may be appreciated that groove <NUM> operates as a pilot hole to receive and contain fastener <NUM>. In one example groove <NUM> is configured to securely receive a fastener such as a screw, including a #<NUM> stainless steel HWH SMS screw. A plurality of screws <NUM> may be inserted along transom to secure a plurality of panels <NUM>, <NUM>' into position. In one instance screws <NUM> may be positioned at <NUM> inches on center. Other arrangements may be used as desired.

<FIG> shows a further example of transom <NUM> having a symmetrically disposed polymer component <NUM>. Also shown is a setting block <NUM> positioned between component <NUM>, particularly, between the stem <NUM> of component <NUM>, and a panel <NUM>. In one example setting block <NUM> is a silicone block of about <NUM> inches to <NUM> inches in length. Block <NUM> may also be a continuous length to match the length of transom <NUM> or in other examples may be a shorter length. Block <NUM> may include a block tip 37a which is a projection from block <NUM> configured to abut component <NUM> for appropriate spacing of block <NUM> beneath panel <NUM> within pocket <NUM>. In one example a number of setting blocks <NUM> may be used and staggered at various locations along the system <NUM>. Blocks <NUM> may be positioned at quarter points along panel <NUM>, for example. Block <NUM> or blocks <NUM> allow for the weight of a panel <NUM> to be transferred to the stem <NUM> or polymer component <NUM>. Use of blocks <NUM> may also be employed with reference to <FIG> and <FIG>. In this manner the weight of panels <NUM> is supported by polymer component <NUM>. Pressure plate <NUM>, which is secured to polymer component <NUM> by a fastener <NUM>, for instance, applies pressure to seals <NUM>, <NUM>, which in turn apply pressure to panels <NUM>,<NUM>'. In one example seal <NUM> may include, for instance, a <NUM>-durometer silicone gasket. The interior side seal <NUM> may include a lineal or molded corner configuration for instance. Pressure plate <NUM> may also include a weep hole <NUM> which is an aperture defined by plate <NUM>. Weep hole <NUM> allows for moisture to escape from pocket <NUM>. A gasket, such as gasket <NUM> may be positioned between pressure plate <NUM> and stem <NUM>. Gasket <NUM> may include a silicone material, such as a <NUM>-durometer silicone gasket separator. It may be appreciated that polymer component <NUM> extends into pocket <NUM> between panels <NUM>, <NUM>'. Pressure plate <NUM> may extend a length of transom <NUM>. Pressure plate <NUM> may include several weep holes <NUM> spaced at various positions along the length of plate <NUM>. In one example weep hole <NUM> may be positioned on pressure plate <NUM> at a position above polymer component <NUM> as shown. This allows water or moisture to escape from below panel <NUM>.

<FIG> shows a further example of transom <NUM> having a symmetrically disposed polymer component <NUM>. In this example the transom <NUM> includes a glazing tape <NUM> between panel <NUM> and component <NUM>. In one example glazing tape <NUM> is a two-sided glazing tape. Use of glazing tape <NUM> secures panel to polymer component <NUM> which is in turn secured to transom wall <NUM>. In addition, a silicone layer <NUM> such as structural silicone is also positioned between panel <NUM> and component <NUM>. Together the glazing tape <NUM> and structural silicone <NUM> secure panel to transom <NUM> while also maintaining a seal relationship. A silicone gasket <NUM> is positioned at an edge of component <NUM> and structural silicone <NUM> for additional insulation and/or for cosmetic purposes to conceal the structure. Gasket <NUM> inserts into a gasket receiver <NUM>' of component <NUM>. A similar arrangement may also be used to secure panel <NUM>' to transom <NUM>. It may be appreciated that use of glazing tape <NUM> and structural silicone <NUM>, for instance, allows for securing panel <NUM> to transom <NUM> without the use of a fastener such as shown the <FIG> or <FIG>. A sealant <NUM> may be applied between panels <NUM>, <NUM>', for instance, and/or applied to stem <NUM> of component <NUM>. A setting block <NUM> may also be used to receive panel <NUM>.

<FIG> shows a further example of transom <NUM> having a symmetrically disposed polymer component <NUM> and where the transom <NUM> is positioned adjacent a horizontal (such as at a bottom area of a curtain wall system). A single (upper) panel <NUM> is used in this example. A PVC spacer <NUM> is positioned between pressure plate <NUM> and component <NUM>. A sealant <NUM> and seal <NUM> may be positioned between the horizontal and cover plate <NUM> and at the joint of component <NUM> and transom wall <NUM>. A setting block <NUM> may be used to set transom <NUM>.

As shown in <FIG>, mullion <NUM> is made of aluminum. Mullion <NUM> is made of a first mullion segment <NUM> and a second mullion segment <NUM>. A polymer component <NUM> is bonded to mullion <NUM>. In one example polymer component <NUM> is bonded, by an adhesive and other bonding techniques, to segment <NUM>. Polymer component <NUM> may include an interlock <NUM> to receive a mullion finger of segment <NUM>. Interlock <NUM> in one example is configured as part of first arm <NUM>. First arm <NUM> may include a lip <NUM> which inserts into a gap defined by segment <NUM>. Adhesive is applied to the surfaces to bond first arm <NUM> to segment <NUM>. Bonding treatments and procedures are used to assure a rigid connection. In one example contact surface <NUM> is bonded to segment <NUM>. Polymer component <NUM> further includes seal receiver <NUM>. Receiver <NUM> is configured to receive a seal <NUM>. In one example seal receiver is defined by seal fingers <NUM>. Seal <NUM> is configured to insert into seal receiver <NUM> and between first arm <NUM> and panel frame <NUM>. Seal <NUM> may be bonded to panel frame <NUM>. Seal <NUM> may be of a conventional variety used in curtain wall systems.

As shown in <FIG>, transom <NUM> further includes shoulder <NUM> laminated or bonded to mullion <NUM>. Particularly shoulder <NUM> is rigidly connected to segment <NUM>. Shoulder <NUM> includes interlock <NUM> which may be the same or similar to interlock <NUM> defined by polymer component <NUM>. Segment <NUM> may also include tail <NUM> which may be friction fit and/or bonded within gap formed by lip <NUM>. Shoulder <NUM> abuts polymer component <NUM> and may include seal <NUM>. Shoulder <NUM> may further include seal receiver <NUM> to receive seal <NUM>. Shoulder <NUM> and polymer component <NUM> are bonded to mullion <NUM> at outer side <NUM> and prevent mullion <NUM> from communication with panels <NUM>, <NUM>' or pocket <NUM>.

With reference to <FIG>, a further example of transom <NUM> is shown which includes transom wall <NUM>. Polymer component <NUM> is bonded to transom <NUM>. Polymer component <NUM> is made of the same or similar material as is the polymer component <NUM> noted above. Polymer component <NUM> is configured to friction fit and/or bond with or to outer side <NUM> of transom <NUM>. In one example polymer component <NUM> includes a lip <NUM> which inserts into a gap formed in part by tail <NUM> of transom wall <NUM>. Transom <NUM> may be made of aluminum and may be extruded, for instance. Lip <NUM> and tail <NUM> create an interlock <NUM>. Polymer component <NUM> further includes a first arm <NUM> which includes a seal receiver <NUM>. Receiver <NUM> is configured to receive a seal <NUM>. In one example seal receiver is defined by seal fingers <NUM>. Seal <NUM> is configured to insert into seal receiver <NUM> and between first arm <NUM> and panel frame <NUM>. Seal <NUM> may be bonded to panel frame <NUM>. Seal <NUM> may be of a conventional variety used in curtain wall systems. Polymer component <NUM> in this example completely covers outer side <NUM> of transom <NUM>.

With reference to <FIG>, an alternative mullion <NUM> which is similar to the mullion <NUM> of <FIG> further includes a fastener <NUM> such as a screw. Fastener <NUM> includes additional support to further inhibit separation of polymer component <NUM> from mullion <NUM>. In one example fastener <NUM> is positioned through first arm <NUM> of polymer component <NUM> and through tail <NUM> of steel segment <NUM>. A sealant may also be inserted to cover the head of fastener <NUM> and to seal the opening (or edges of the opening) which is created by fastener <NUM>. Use of fastener <NUM> provides enhanced protection in the event of a fire situation where temperatures can be extreme. It is envisioned that the bonding of polymer component <NUM> (and shoulder <NUM>) will withstand very high temperatures without separation and/or with use of fastener <NUM> such separation will be inhibited or prevented. Polymer component <NUM> is made of fire-retardant material. Accordingly, the features presented in <FIG> provide a mullion with an enhanced fire rating.

<FIG> shows transom <NUM> where fastener <NUM> is inserted through polymer component <NUM> where polymer component <NUM> is also bonded to transom <NUM>. This arrangement has similar separation inhibiting example as noted with <FIG>.

<FIG> shows a polymer component <NUM> bonded to mullion <NUM>. In this example mullion <NUM> includes first mullion segment <NUM> having a tail 31a leading to arm 31b and hand 31c. Arm 31b extends from tail 31a in a generally perpendicular orientation. Hand 31c extends from arm 31b in a generally perpendicular orientation. Component <NUM> is bonded to segment <NUM> at tail 31a, arm 31b and hand 31c. Mullion <NUM> also includes second mullion segment <NUM> which includes shoulder polymer component <NUM>. Component <NUM> is made of the same or similar material as component <NUM>. Component <NUM> is bonded to segment <NUM> at tail <NUM>. It may be appreciated that the exterior surface of tail <NUM> is covered from the atmosphere or from communication with panel <NUM>' or pocket <NUM>. It may also be appreciated that the exterior surface of segment <NUM>, such as at tail 31a, arm 31b and hand 31c, is also covered from the atmosphere or from communication with panel <NUM> or pocket <NUM>. Component <NUM> may wrap at least in part at a tip of tail <NUM>. Component <NUM> and component <NUM> include seal receiver <NUM>, <NUM>' to receive respective seals <NUM>.

<FIG> shows a polymer component <NUM> and a polymer component <NUM> bonded to mullion <NUM>. The bonding is achieved by use of an adhesive applied. In this example component <NUM> is devoid of a stem and does not include an element which projects into pocket <NUM>. Panels <NUM>, <NUM>' are secured to component <NUM> and component <NUM>, respectively, with glazing tape <NUM> and structural silicone <NUM>. A sealant <NUM> and seal <NUM> are applied between panels <NUM>, <NUM>'.

<FIG> shows a polymer component <NUM> bonded to mullion <NUM>. In one example mullion <NUM> is formed of bent sheet steel. In this view mullion <NUM> is positioned adjacent or against a vertical wall and connects with a transom <NUM> having wall <NUM>. Transom <NUM> also includes an end plate <NUM> welded at an end of transom <NUM>. End plate <NUM> receives fasteners which pass through mullion <NUM>. A single segment mullion <NUM> is configured with opposing walls <NUM>, <NUM>' to accommodate adherence of fingers 141a, 141b. Segment <NUM> is bonded to mullion <NUM> as noted above with respect to the further examples. Segment <NUM> includes seal receivers <NUM>, <NUM>' to receive a seal <NUM> and/or a PVC spacer <NUM>. It may be appreciated that an entirety of an outside surface of mullion <NUM> is isolated from the atmosphere or from communication with panel <NUM>' and/or pocket <NUM>. It may be appreciated that panel <NUM>' may also be fastened to mullion <NUM> by use of glazing tape and silicone gasket as desired (and as an alternative to use of a fastener and/or stem <NUM>).

While there are some curtain wall systems made of metal, most are made of aluminum. Some curtain wall installers may not appreciate the difficulties in working with steel systems due to the need to assure non-exposure of parts to the atmosphere or water which would otherwise result in deterioration, or for other reasons (or if they do, the exactness of the installation may require extra time and expense to complete the project). A tradesman accustomed to installing aluminum systems might be more apt to make a mistake in dealing with steel, or if a mistake is made, the resulting damage is, or can be, much more significant as compared to a mistake in installing an aluminum system.

Accordingly, use of a system where the fiberglass reinforced polymer elements act as the stem and/or cover the face side of mullion <NUM> (or transom <NUM>) is desired. It would not matter if an installer would be concerned about confronting a steel mullion structure as opposed to an aluminum structure since either may be configured to prevent exposure of the frame element (while also providing improved insulating aspects).

Mullion <NUM> may be of varying lengths depending on the desired application. In one example, mullion <NUM>, and thus segment <NUM> may have a length of up to <NUM> feet, or at least <NUM> feet. A press that is <NUM> feet long, or at least <NUM> feet long may be used to form mullion <NUM> at such length. Mullion <NUM> may also be of smaller length as desired and smaller presses and tooling may also be used. Mullion <NUM> may be formed at a variety of widths. In one example mullion <NUM> may vary in width from <NUM>¾ inches (<NUM>), for instance, to <NUM> inches (<NUM>) or more, and may vary in depth from <NUM> inches (<NUM>), for instance, up to <NUM> inches (<NUM>) or more. Different lengths, widths and depths and other dimensions may also be used as desired.

All of such variously dimensioned mullions and transoms and individual segments can be manufactured using the same tooling and break press machine in a bending process. In another example mullion and transom may be manufactured using a roll forming technique. In a roll forming technique different tooling would be used to manufacture mullions or transoms having different dimensions. By utilizing the same break press machine and tooling, however, a variety of dimensions with custom or various profiles may be formed at lower cost. Steel cannot be extruded or is extremely difficult or impossible to extrude with present or typical machinery or methods. Bending of steel is used to provide the profile as shown in the Figures, for example.

The bending of steel by use of a press brake and tooling to make curtain wall components or segments as presented at such lengths and tolerances has heretofore never been done before or even appreciated as being capable of accomplishment (despite a long-felt need in the market). This is remarkable especially due to the complexities, uncertainties and difficulties given the need for particular tolerances and lengths of products and equipment, together with the difficulties in handling the products and the precise nature required for creating the products and associated equipment. There has been a lack of appreciation of the opportunity to utilize press-brake bending of steel for creating curtain wall segments. Press break bending has not been utilized for creating curtain wall products having lengths of <NUM> feet, or even greater than <NUM> feet. Applicant appreciates the difficulty in obtaining or maintaining required tolerances along the entire length of the segments, for instance, the need to have clean or complete folds or bends (which also avoid facture or cracking during forming) that run uniformly along the entire profile length of the lengthened steel products. An added benefit of using a press brake forming process is that the steel curtain wall segments may be customized to accommodate different depths or other dimensions (while still maintaining desired tolerances and long lengths) without having to purchase or design new equipment or tooling.

Also described herein is a method of bending sheets of steel to make a variety of curtain wall mullion or transom segments and bonding a fiber reinforced polymer element to the structure such that the bonded element extends into a gap defined by two adjacent panels supported by the system. The method includes using a press brake and a set of tooling elements configured for use in conjunction with the press brake to bend a sheet of steel to form a first mullion segment. The bonded segment has a polymer component. The method further includes using the press brake and at least some of the same tooling elements (or all of the same tooling elements) to bend a second sheet of steel to form a second mullion segment. The bonding process may include use of adhesives and curing agents and application of temperature or other bonding techniques to assure a rigid formation of the polymer component to the mullion or transom structure.

Also described herein is a method of making a thermally insulating component configured to be bonded to a metal structure where the method comprises pultruding the component with a thermally insulating material through a pultrusion die having a profile perpendicular to the direction of pultrusion including a stem <NUM> extending in a first direction from a base <NUM>, first arm <NUM> and second arm <NUM> extending from opposite sided of base <NUM> and each extending perpendicular to the stem <NUM> and each defining a seal receiver <NUM> having an opening toward the first direction. In a further example the stem <NUM> includes a groove <NUM> configured to receive a fastener <NUM>. Groove <NUM> may include a taper <NUM> to assist in receiving fastener <NUM>. Groove <NUM> may be a continuous groove which spans the length of component <NUM>, <NUM>. It may be appreciated that groove <NUM> operates as a pilot hole to receive and contain fastener <NUM>. In one example groove <NUM> is configured to securely receive a fastener such as a screw, including a #<NUM> stainless steel HWH SMS screw. In a further example the component profile includes a first finger 141a and a second finger 141b each extending from base <NUM> opposite stem <NUM>. Fingers <NUM> are configured to align with a curve of metal structure <NUM>, and particularly configured to conform to opposing hands <NUM>, <NUM>'. While other arrangements are available, in one example fingers <NUM> are symmetrically separated by a distance greater than the width "w" of stem <NUM>. The thermally insulating component <NUM> may be pultruded from fiberglass material and may also include reinforcing mats and an exterior surface may include a heat set resin coating. In further examples the invention includes the method of pultruding the various thermally insulating components <NUM>, <NUM> (and components <NUM>, <NUM>, <NUM>) as described herein.

Also described herein is a method of bonding a thermally insulating component to a metal structure. The metal may include steel, aluminum, alloys or other metals. In one example the method includes providing an adhesive between a pultruded fiberglass material and an outer side <NUM> of metal structure <NUM>. In one example the fiberglass material is a polymer component <NUM> having fingers <NUM> that fit with respective hands <NUM> of the metal structure <NUM>. In further examples the method includes bonding the component <NUM> to the cover the entirety of the outer side <NUM> of metal structure <NUM>.

<FIG> is a section view showing the claimed invention. Transom <NUM> is a metal structure and includes a metal first segment <NUM> and a metal second segment <NUM> connected thereto. Segments <NUM>, <NUM> may be made of extruded metal such as aluminum. Segment <NUM> may snap-fit into connected position. Transom <NUM> has an outer side <NUM> which is oriented toward or facing panels <NUM> or an outside of the building to which transom <NUM> is connected. Segment <NUM> includes an access port <NUM> such that when segment <NUM> is not connected to segment <NUM>, access is made available to inside <NUM> of transom <NUM>. Particularly, access may be made through port <NUM> such that a fastener <NUM> can be inserted into and through segment <NUM>. Fastener <NUM> is inserted such that a head 39a of fastener <NUM> abuts inner surface <NUM> of transom <NUM>. Fastener <NUM> is inserted through segment <NUM> to outer side <NUM> of transom <NUM>.

Transom <NUM> includes a component <NUM> connected to transom <NUM> at outer side <NUM>. Component <NUM> may be made of materials noted above regarding components <NUM>, <NUM>. In one embodiment component <NUM> includes a head <NUM> which inserts into a pocket <NUM> of segment <NUM>. Head <NUM> may include ear or ears <NUM> which in one embodiment insert into interlocking slots <NUM> defined at least in part by pocket rib <NUM>. Component <NUM> also includes shoulder <NUM> or opposing shoulders <NUM> which abut transom <NUM> at outer side <NUM>. Particularly, shoulder <NUM> abuts and covers outer side face <NUM>' of segment <NUM>. It may be appreciated that component <NUM> abuts and covers the entirety or substantially the entirety of outer side <NUM> of segment <NUM>. Covering the entirety of outer side <NUM> isolates the metal transom <NUM> from the outside and insulates transom <NUM>. Component <NUM> also defines a bore such as head bore <NUM> which is configured to receive fastener <NUM>. Head bore <NUM> opens toward head <NUM> such that fastener <NUM> penetrates through segment <NUM> and into bore <NUM>. Bore <NUM> is a closed bore in that bore <NUM> is closed opposite head <NUM> (i.e., the bore does not run through the component). In this manner component <NUM> may be fastened to transom <NUM> without exposing any part of transom or outer side <NUM> to the elements. There are no perforations made through component <NUM> which would otherwise tend to cause moisture or cold or outside air to contact transom <NUM>. Bore <NUM> also allows for efficient insertion or securing of fastener <NUM> to component <NUM>. Given the nature of the materials used to make component <NUM> (reinforced fiberglass), bore <NUM> allows the fastener <NUM> to penetrate or connect to component <NUM> without undue trauma to component <NUM>. The absence of bore <NUM> might otherwise cause component <NUM> to splinter or crack or otherwise become weak when fastener <NUM> is inserted. In one instance fastener <NUM> includes self-threading threads which impart corresponding thread grooves in component <NUM> at bore <NUM>. Opposite from bore <NUM> is stem bore <NUM> defined by stem <NUM>. Bore <NUM> receives a fastener <NUM>. Fastener <NUM> may secure pressure plate to transom <NUM>. Bore <NUM> opens outward and has a closed end or bottom oriented toward segment <NUM>. Shoulder <NUM> may include a seal receiver <NUM> to receive a seal <NUM>. Seal <NUM> abuts panel <NUM>. A spacer or setting block <NUM> is positioned on component <NUM> at stem <NUM>. Upon block <NUM> rests panel <NUM>. It may be appreciated that panel <NUM> will have a weight and the weight is supported by component <NUM>. Component <NUM> extends between or into a gap between panels <NUM>, <NUM>. In this manner component <NUM> is a structural support of panel <NUM>. It may be appreciated that component <NUM> extends the entire length or substantially the entire length of the face or outer side <NUM> of segment <NUM>.

In some embodiments component <NUM> is positioned within pocket <NUM> of segment <NUM> by longitudinally inserting head <NUM> into pocket <NUM> and sliding component <NUM> longitudinally within pocket <NUM>. Component <NUM> and segment <NUM> may be placed end-to-end for sliding action. Once head <NUM> and component <NUM> are slid into position within pocket <NUM>, a fastener <NUM> or series of fasteners may be secured to transom <NUM>. Particularly, a fastener <NUM> is positioned to inside <NUM> and placed against inner surface <NUM>. A drill or screwdriver is activated to drive fastener <NUM> through segment layer <NUM> and into bore <NUM> of head <NUM> of component <NUM>. A series of fasteners <NUM> may be inserted along the longitudinal aspect of component <NUM>. Fasteners <NUM> may be inserted via angled drill/drive devices. Fasteners <NUM> may be inserted robotically. After insertion of fasteners <NUM>, second metal segment <NUM> is connected to first metal segment <NUM> to form transom structure <NUM>. In a further embodiment, component <NUM> may also be bonded to metal segment <NUM>. In one instance shoulder <NUM> may be bonded to outer side face <NUM>' with an adhesive. A heat treatment may also be applied to assist with the bonding. An adhesive layer may also be inserted into or used to fasten shoulder <NUM> to segment <NUM>. Adhesive may also be used to secure head <NUM> within pocket <NUM>. Various designs and configurations of head <NUM> may be used.

Component <NUM> is a thermally insulating fiberglass reinforced polymer component <NUM>. Component <NUM> is for use with a curtain wall mullion <NUM> or transom of a curtain wall system. In some embodiments component <NUM> includes a head <NUM> configured to insert into a pocket <NUM> defined at an outer side <NUM> of a metal mullion or transom <NUM> of the system. Opposing shoulders <NUM> define seal receivers <NUM> configured to receive a seal oriented to abut a panel <NUM> of the system. Each of the shoulders <NUM> are configured to about the outer side <NUM> of the metal structure <NUM> such that component <NUM> covers substantially an entirety of the outer side <NUM>. As shown in <FIG>, component <NUM> covers the entirety of the outer side <NUM> at outer side face <NUM>'. A stem <NUM> is configured to project into a space between a first panel <NUM> and a second panel <NUM> of the system. Stem <NUM> provides structural support of the panel <NUM>. Component <NUM> comprises a unitary thermally insulating fiberglass reinforced polymer. In some embodiments component <NUM> comprises pultruded fiberglass reinforced polymer. The head <NUM> defines a head bore <NUM> configured to receive a fastener <NUM> inserted through the metal structure <NUM> and into the component <NUM>. In embodiments, stem <NUM> defines a stem bore <NUM> configured to receive a fastener <NUM>. The fastener <NUM> received in stem bore <NUM> may be of a different, or the same, variety as the fastener received at head bore <NUM>. Stem bore <NUM> in one embodiment is oriented opposite head bore <NUM>.

<FIG> is a section view of a further embodiment of the claimed invention. Transom <NUM>' is a steel transom having a steel first segment <NUM>' and a metal second segment <NUM>' which may also be made of steel. Segment <NUM>' may slide into connected position and friction fit into secure placement. Access port <NUM>' is used to insert fastener <NUM> through segment <NUM>' and into component <NUM>. Shoulder <NUM>' is connected to outer side face <NUM>. An adhesive and heat and pressure techniques may be used to secure or bond shoulder <NUM>' to outer side face <NUM>'. An adhesive layer may be inserted between shoulder <NUM>' and face <NUM>'. Fastener <NUM> is inserted from within segment <NUM>'. Several fasteners <NUM> may be inserted though segment <NUM>' to secure component <NUM> along the longitudinal length of segment <NUM>'. It may be appreciated that with the design of pocket <NUM>' (which lacks ribs <NUM>), head <NUM> of component <NUM> may be inserted by translating component <NUM> into the pocket <NUM>' and without requiring a longitudinal sliding action.

<FIG> is a section view of a further embodiment of the claimed invention. Mullion <NUM> is an aluminum mullion having first segment <NUM> and a second segment <NUM> connected thereto. Fastener <NUM> is positioned at inside <NUM> of mullion <NUM> and driven through wall of segment <NUM> into component <NUM>. Component <NUM> includes a head which inserts into pocket <NUM>. Pocket ribs <NUM> may be used as interlock elements to assist in locking component <NUM> or aligning component <NUM> within pocket <NUM>. An additional component <NUM> is connected to segment <NUM> such that together component <NUM> and component <NUM> cover an entirety or substantially the entirety of outer side <NUM> of mullion. Component <NUM> may be made of the same or similar material used to make component <NUM>, namely a fiberglass reinforced polymer, and in some embodiments may be an insulating pultruded fiberglass reinforce polymer.

<FIG> is a section view of a further embodiment of the claimed invention. Mullion <NUM>' is a steel mullion having a first segment <NUM>' and a second segment <NUM>' connected thereto. Second segment <NUM>' may also be made of steel. Component <NUM>' is secured to segment <NUM>' with a fastener <NUM>. An optional washer may be placed between fastener <NUM> and the inner surface <NUM> of segment <NUM>'. An optional washer may also be used with the other embodiments described herein. A second component <NUM>' is connected to segment <NUM>'. Component <NUM>' may be bonded to segment <NUM>'. Second component <NUM>' may also be connected to segment <NUM>' with a fastener which runs from inside <NUM>' of mullion <NUM> through a wall of transom segment, either <NUM>' or <NUM>', and into component <NUM>'.

<FIG> is a section view of a further embodiment of the claimed invention. Mullion <NUM> includes a metal segment <NUM> and a second metal segment <NUM> which slide together for an adjustable connection. For instance, segments <NUM>, <NUM> may slide relative to each other in the direction of arrow A to form a mullion <NUM>. A fastener <NUM> inserts from inside <NUM> of segment <NUM> through a wall of segment <NUM> and into component <NUM>. Component <NUM> is made of a polymer material as noted herein. Component <NUM> is connected to segment <NUM> by fastener <NUM>. Interlock rib <NUM> may be used to form an interlock to secure component <NUM> within a pocket <NUM>. Component <NUM> is slid longitudinally into pocket <NUM> to be secured to segment <NUM> and/or secured via fastener <NUM> and/or both. An adhesive may also be used to secure component <NUM> to segment <NUM>. An adhesive bonding may be used together with a fastener and also together with an interlock as desired. As shown in <FIG>, a rib or ribs and pocket similar to rib <NUM> and pocket <NUM> may also be provided by segment <NUM> to secure component <NUM>. An interlock and/or fastener <NUM> and/or both and/or adhesive and/or all of such connections may be used to connect component <NUM> to segment <NUM>. An adhesive may also be used, including an adhesive layer together with heat and pressure treatments used to bond or secure component <NUM>, <NUM> to mullion <NUM>.

Component <NUM>, <NUM> includes stem <NUM> which extends between panels <NUM>. A leg <NUM> wraps laterally and over (and covers) a portion of panel <NUM> as shown. A portion of panel <NUM> is also covered by shoulder <NUM>. Shoulder <NUM> and leg <NUM> each define a seal receiver <NUM>. Component <NUM> may be secured to segment <NUM> using several fasteners <NUM>. Thereafter panel <NUM> may be secured using component <NUM> and with seal placed in seal receivers <NUM> and adhered to panel <NUM>. Likewise, component <NUM> may be fastened to segment <NUM> with several fasteners <NUM> and then panel <NUM> connected to component <NUM> by use of seals and adhesive. Segment <NUM> and segment <NUM> may then be slid or adjustably connected together. The segments <NUM>, <NUM> may also be conveniently disconnected by relative sliding along direction of arrow A. When segments <NUM>, <NUM> have been connected together, mullion <NUM> may be connected to the building structure. It may be appreciated that an entirety or substantially the entirety of outer side <NUM> of combined segment <NUM>, <NUM> (or of individual segments <NUM>, <NUM>) is covered by components <NUM>, <NUM> with portions of components <NUM>, <NUM> contacting segments <NUM>, <NUM>. Further, it may be appreciated that no pressure plate or exterior fastener is required to secure panel <NUM> to segments <NUM>, <NUM>. In one embodiment, components <NUM>, <NUM> comprise pultruded fiberglass polymer and are configured to wrap about the edge of panel <NUM>. Components <NUM>, <NUM> define bore <NUM> to receive fasteners <NUM>.

<FIG> is a section view of a further aspect of the invention. transom <NUM> which includes metal segment <NUM> and metal segment <NUM> connected thereto. A wing <NUM> projects from segment <NUM> to a gap between panels <NUM>, <NUM>. Fastener <NUM> is secured through wing and into component <NUM>. Component <NUM> may include a bore to receive fastener <NUM>. In one example wing <NUM> projects perpendicularly or generally perpendicularly from outer side face <NUM>'. In one example, fastener <NUM> is oriented perpendicular or generally perpendicular to wing <NUM>. Component <NUM> may be a polymer component as described herein. A second component <NUM> is connected to segment <NUM>. Component <NUM> may be connected via adhesive or bonding. A fastener may also be secured from and through inside of segment <NUM> and into component <NUM>. In further examples component <NUM> may include a bore to receive a fastener. Component <NUM> wraps around to both sides of panel <NUM> as shown. An entirety of outer side <NUM> of combined segment <NUM>, <NUM> is covered by components <NUM>, <NUM>, <NUM>. Such components <NUM>, <NUM>, <NUM> also contact outer side <NUM> of segments <NUM>, <NUM>. Component <NUM> may include an interlock which inserts into a corresponding interlock of segment <NUM>. Component <NUM> may also include a seal receiver which receives a seal to abut against panel <NUM>. An additional component <NUM> may be used to cover wing <NUM> as shown and to provide further insulating protection of segments <NUM>, <NUM>. Component <NUM> may be connected to wing <NUM> by adhesive and/or a fastener. A further component <NUM> includes a seal receiver and receives a seal to abut against panel <NUM>. Component <NUM> may comprise a metal or in other examples may also comprise a fiberglass component. An end of component <NUM> opposite seal receiver includes a rib or ribs which insert into corresponding rib or ribs of component <NUM> for secure positioning of component <NUM>. In addition to use of fastener <NUM>, or as an alternative to fastener <NUM>, an adhesive may be used to rigidly bond component <NUM> to outer side face <NUM>'. Such bonding may be made by use of an adhesive and other forms of bonding may also be used. Additionally, or alternatively, a rib <NUM> may also be used to secure or assist in rigidly securing component <NUM> to face <NUM>'. A spacer may be inserted into cavity <NUM> of transom <NUM> so that panel <NUM> may rest against the spacer so that the weight of panel <NUM> may be supported by component <NUM>. Component <NUM> may also include a weep hole or weep holes to allow moisture to escape from cavity <NUM>.

<FIG> is a section view of a further aspect of the invention. transom <NUM> which includes metal segment <NUM> which may be aluminum for instance. Segment <NUM> mates with segment <NUM> which may also be made of metal such as aluminum. Component <NUM> is connected to outer side <NUM> of transom <NUM>. In one example component <NUM> connects to wing <NUM> and is configured to cover the entire outer side of segment <NUM>. Component <NUM> may include a bore configured to receive fastener <NUM> inserted through wing <NUM>. An adhesive may also be used to secure component <NUM> to segment <NUM>. A strip or sheet of double back adhesive may be used. Heating, pressure and additional bonding techniques may be used to connect a component to the metal herein. Various interlocks, ribs and grooves may also be used to secure component <NUM> to segment <NUM>. Segment <NUM> may include a rib <NUM> or ribs which mate with component <NUM> for interlocking arrangement. Component <NUM> may include leg <NUM> which extends to an outer side of panel <NUM> and transom <NUM> and may include a seal receiver to receive a seal to abut against panel <NUM>. Component <NUM> may also include a weep hole <NUM> or a series of weep holes to allow moisture to escape from cavity <NUM>. Component <NUM> includes a further seal receiver to receive a seal to abut panel <NUM> on an inner side of panel <NUM>. It may be appreciated that component <NUM> wraps around to both sides of panel <NUM>. A spacer may also be positioned in cavity <NUM> so that panel <NUM> may rest upon the spacer which in turn rests upon component <NUM>. Component <NUM> supports the weight of panel <NUM>.

A component <NUM> is connected to segment <NUM> at jaw <NUM>. The entirety of the outer side of jaw <NUM> is covered by component <NUM>. Component <NUM> wraps around a tip of jaw <NUM>. Component <NUM> includes a seal receiver for receiving a seal to abut against an inside of segment <NUM>. An optional air baffle <NUM> is placed within segment <NUM>. In one example baffle <NUM> may be about <NUM> inches in length and is positioned where the vertical mullion terminates or at the top of the vertical mullion to prevent air leaks. In one example baffle <NUM> fits snugly into a channel defined in part by various walls of segment <NUM> as shown. A tip of jaw <NUM> inserts into the channel and the component <NUM> abuts baffle <NUM> which also seals outer face of segment <NUM> from exposure. Segment <NUM> is also connected to segment <NUM> and covers wing <NUM> and isolates wing <NUM> and walls of segment <NUM> from the atmosphere or exposure. It may be appreciated that components <NUM>, <NUM> may be secured to segments <NUM>, <NUM> by adhesive, including a double backed strip adhesive and under pressure and temperature for bonding. In alternative examples components <NUM>, <NUM> may also be fastened with a fastener. Components <NUM>, <NUM> may also define respective bores for receiving fasteners. Components <NUM>, <NUM>, <NUM> may be secured by use of adhesive and/or fasteners and/or interlock/friction fit or all of the same. An end cap <NUM> connects securely to component <NUM> via friction fit or snap-on fingers and includes a seal receiver and seal to abut panel <NUM> which is held in place at panel <NUM>. An adhesive block or connector <NUM> is used to secure panel <NUM> to segment <NUM>. It may be appreciated that segments <NUM> and <NUM> come together to form transom <NUM> and the individual segments <NUM>, <NUM> are connected to respective structure elements of the building to secure transom <NUM> and panels <NUM> into position. While the unitized design shown in <FIG> depicts a transom made of metal such as aluminum, it may be appreciated that such transom structure may also be made with steel, of course with some structural modifications to accommodate for the bending of the steel segments comprising the transom.

Claim 1:
A curtain wall mullion or transom for use on a curtain wall system, the mullion or transom comprising:
a metal mullion or transom structure (<NUM>, <NUM>', <NUM>, <NUM>', <NUM>) having an outer side (<NUM>, <NUM>, <NUM>); and
a fiberglass reinforced thermally insulating polymer component (<NUM>, <NUM>/<NUM>, <NUM>'/<NUM>', <NUM>/<NUM>) having a width which spans a total width of the outer side of the metal mullion or transom structure (<NUM>, <NUM>', <NUM>, <NUM>', <NUM>),
wherein the component (<NUM>, <NUM>/<NUM>, <NUM>'/<NUM>', <NUM>/<NUM>) abuts the outer side of the structure (<NUM>, <NUM>', <NUM>, <NUM>', <NUM>) and covers the entirety of the outer side of the structure (<NUM>, <NUM>', <NUM>, <NUM>', <NUM>), the component (<NUM>, <NUM>/<NUM>, <NUM>'/<NUM>', <NUM>/<NUM>) being connected to the metal structure (<NUM>, <NUM>', <NUM>, <NUM>', <NUM>) at the outer side by a first fastener (<NUM>) having a head, characterized by
the first fastener (<NUM>) passing through the metal structure (<NUM>, <NUM>', <NUM>, <NUM>', <NUM>) and into the component (<NUM>, <NUM>/<NUM>, <NUM>'/<NUM>', <NUM>/<NUM>), the head (39a) positioned at an inside of the structure (<NUM>, <NUM>', <NUM>, <NUM>', <NUM>).