Patent Description:
Buildings are the number one end users of energy. They are responsible for about <NUM>% of all energy consumption and carbon emissions in both developed and developing countries. One of the main reasons behind such huge consumption is that the majority of the existing building stock today is over <NUM> years old, and thus, most existing buildings have under-performing and inefficient building systems compared to the current technologies. That is why many cities that have recently committed to reducing their greenhouse gas emissions have started to target the energy efficiency of the existing building stock with measures that address all building systems, particularly those associated with and influenced by the building envelope.

The significance of the building envelope comes from the fact that its thermal performance and weather tightness determine the amount of energy needed to maintain a comfortable indoor environment relative to the outdoors. In fact, building envelope components can significantly impact heating, cooling, and ventilation loads in addition to lighting, which are the main areas of energy consumption in building operations. For example, it is estimated that about one third of the energy consumed in commercial buildings for heating and cooling is associated with windows.

Taking that into consideration, several research reports have highlighted that <NUM>-<NUM>% of the total energy savings in buildings is projected to be from windows and building envelopes. This is because up until the <NUM>, windows, curtain walls, and skylights were mainly single-glazed with frameworks that had no thermal breaks. These inefficient glazing systems result in significant heat loss in the winter and heat gain in the summer, and thus, lead to higher energy consumption for heating and cooling to maintain a comfortable indoor environment.

Today, it is estimated that about <NUM>% of all commercial and multi-family residential buildings in the United States, for example, still have single-pane windows, and about half of the remaining <NUM>% have early or low-performing double-pane window systems that lack significantly in performance compared to the current technologies and building and energy code requirements. The problem is that replacing these inefficient glazing systems with new, high-performing ones is often not a feasible option for most buildings due to the associated complexity, high upfront costs, building and business disruption, and long payback periods.

Additionally, most glazing systems, including the current ones, are still being designed with little consideration (if any) given to the high possibility of them requiring a retrofit in the future, leaving building owners with limited options when the need arises. That is why most façade and window retrofit practices available today include intrusive and complex measures that are associated with high upfront costs, building and business disruption, and long payback periods as well, and thus, they are often not considered a feasible option for most buildings.

Therefore, there is a growing technical and environmental need for feasible glazing and window retrofit solutions that can be widely adopted by most existing buildings to improve their energy efficiency. In <CIT> a retrofit panel is attached to the mullions and transoms of the curtain wall.

A glazing shield system and a method for retrofitting glazing systems of buildings are disclosed. The glazing shield system comprises a support frame and a unitized panel. In certain embodiments, the glazing shield system may be mounted on an existing glazing system in a non-intrusive and non-destructive method. In one embodiment, the support frame may be attached to an infill panel of an existing glazing system using structural adhesives, and the unitized panel may be mounted on the support frame, trapping a volume of air between the infill panel of the existing glazing system and the unitized panel of the present disclosure, creating an insulating glazing shield.

These and other features, and advantages, will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings. It is important to note the drawings are not intended to represent the only aspect of the invention.

For the purposes of promoting an understanding of the principles of the present inventions, reference will now be made to the embodiments, or examples, illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, the scope of the invention being defined by the claims.

When directions, such as upper, lower, top, bottom, clockwise, counterclockwise, are discussed in this disclosure, such directions are meant to only supply reference directions for the illustrated figures and for orientation of components in the figures. The directions should not be read to imply actual directions used in any resulting invention or actual use. Under no circumstances, should such directions be read to limit or impart any meaning into the claims.

Well-known elements are presented without detailed description in order not to obscure the present invention in unnecessary detail. For the most part, details unnecessary to obtain a complete understanding of the present invention have been omitted inasmuch as such details are within the skills of persons of ordinary skill in the relevant art. Details regarding control circuitry or control devices are within the skills of persons of ordinary skill in the relevant art. Consequently, such devices, circuits, and controllers, have been simplified to illustrate elements that are relevant for a clear understanding, while eliminating, for the purpose of clarity, many other elements found in such electronics. Those of ordinary skill in the art may recognize that other elements and/or steps are desirable and/or required in implementing certain controllers and electric circuits. However, because such elements and steps are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements and steps is not provided herein.

<FIG> is an isometric drawing illustrating a portion of an exemplary existing glazing system <NUM>. In the illustrated embodiment, the existing glazing system <NUM> may be a mechanically-glazed, stick-built curtain-wall system, which typically comprises anchor assemblies <NUM>, vertical meeting rail assemblies <NUM>, horizontal meeting rail assemblies <NUM>, and infill panels <NUM>. The anchor assemblies <NUM> are typically attached to the building structure <NUM>, such as concrete floor slabs, and are used to transfer the load of the stick-built curtain-wall to the building structure. For purposes of illustration, the existing infill panels <NUM> may be monolithic glass panels.

<FIG> illustrates a vertical section view of a typical existing horizontal meeting rail assembly <NUM> joining an upper portion of an existing infill panel 48a and a lower portion of an existing infill panel 48b. Because details of existing meeting rail assemblies vary widely, such details will not be discussed in depth here. Generally, however, for the horizontal meeting rail assembly <NUM>, there is a transom <NUM> and a transom cover <NUM> which couples to the transom <NUM> via an attachment system, such as a plurality of bolts <NUM> and a base plate <NUM>. In certain embodiments, there may be some form of seals or gaskets <NUM> positioned adjacent to the perimeter of the infill panels 48a and 48b where they couple to the horizontal meeting rail assembly <NUM>.

In contrast, <FIG> illustrates a horizontal section view of a typical vertical meeting rail assembly <NUM> joining a left side portion of an existing infill panel 48c and a right side portion of an existing infill panel 48d. Generally, the vertical meeting rail assembly <NUM> may include a mullion <NUM> and a mullion cover <NUM> which couples to the mullion <NUM> via an attachment system, such as a plurality of bolts <NUM> and a base plate <NUM>. In certain embodiments, there may be some form of seal or gaskets <NUM> positioned adjacent to the perimeter of the infill panels 48c and 48d where they couple to the vertical meeting rail assembly <NUM>.

The infill panels <NUM> may be any type of vision, spandrel, or shadow box glazing infill panel or any type of metal cladding infill panel. The panels <NUM> may be any type of monolithic, laminate, double-, triple-, or multi-pane panel of any configuration, or any other type of glazing infill panel.

The existing glazing system <NUM>, shown in <FIG>, <FIG>, and <FIG> is exemplary only and is not intended to limit the scope of the invention in any way. The present invention may readily be used with a wide variety of new and existing glazing systems including, but not limited to, single-, double-, or multi-pane glazing systems, mechanically- or structurally-glazed systems, point-fixed glazing systems, stick-built and unitized curtain-walls, window-walls, fixed and operable windows, doors, skylights, sloped glazing, and the like.

<FIG> is an isometric drawing illustrating one embodiment of a glazing shield system <NUM> mounted on an infill panel, such as the existing infill panel <NUM> of the glazing system <NUM> illustrated in <FIG>, discussed above. <FIG> is an exploded drawing of the glazing shield system <NUM>, which typically comprises a support frame <NUM> and a unitized panel <NUM>. In certain embodiments, the glazing shield system <NUM> may be mounted to the existing infill panel <NUM> in a non-intrusive and non-destructive method. In certain embodiments, the support frame <NUM> may be attached to the infill panel <NUM> using a peripheral attachment means or mechanism, such as structural adhesives, which as will be explained later, are applied to one face of a peripheral area of the infill panel <NUM>.

In contrast, the unitized panel <NUM> may be mounted on the support frame <NUM> by mating with one or more mechanical mechanisms as discussed below. In certain embodiments, when the unitized panel <NUM> is mounted to the support frame <NUM> (which in turn, is mounted to the existing infill panel <NUM>), a volume of air is then trapped between the infill panel <NUM> of the existing glazing system <NUM> and the unitized panel <NUM> of the present disclosure, creating an insulating glazing shield.

Turning to <FIG>, there is an isometric drawing of the support frame <NUM> of the glazing shield system <NUM>. In one embodiment, the support frame <NUM> comprises a top rail assembly <NUM>, bottom rail assembly <NUM>, and first side rail assembly <NUM> and a second side rail assembly <NUM>. The top, bottom, and side rail assemblies <NUM>, <NUM>, <NUM>, <NUM> further comprise a top rail member <NUM>, a bottom rail member <NUM>, a first side rail member <NUM>, and a second side rail <NUM>, respectively. In one embodiment, the top, bottom, and side rail members <NUM>, <NUM>, <NUM>, <NUM> may be made up of an extruded metal, such as aluminum. In an alternate embodiment, the top, bottom, and side rail members <NUM>, <NUM>, <NUM>, <NUM> may be made up of an extruded composite or polymer-based material, such as vinyl, polyvinyl chloride (PVC), or unplasticized polyvinyl chloride (uPVC), for better thermal performance. An additional metal piece or extrusion may be used with the composite or polymer-based profiles for better adhesive bonding and structural performance.

In some embodiments, rail members, such as side rail members <NUM> and <NUM> may have a plurality of openings. Certain openings, such as openings <NUM> are designed to engage a series of protrusions (not shown) which may assist in coupling the unitized panel <NUM> to the support frame <NUM> - as will be explained below. In other embodiments, other openings, such as openings <NUM> are designed to reduce the overall weight of the support frame <NUM>. In yet other embodiments, various components, such as control components or desiccant elements, may reside in compartments and/or spaces created by such openings <NUM>.

<FIG> is a vertical section view of the existing horizontal meeting rail assembly <NUM> of the glazing system <NUM> as illustrated in <FIG> with the addition of two support frames positioned above and below the transom cover <NUM>. As illustrated in <FIG>, there is an upper portion of support frame 102a, which includes the top rail member <NUM> and a lower portion of a support frame 102b which includes the bottom rail member <NUM>. The top rail member <NUM> is shaped to include an interconnecting or anchoring means, which in certain embodiments, may include a hook-like protrusion <NUM>. Similarly, the bottom rail member <NUM> is shaped to include an interconnecting or anchoring means which may also include a hook-like protrusion <NUM>.

In addition to interconnecting features, the top rail member <NUM> and the bottom rail member <NUM> may be shaped in cross-section to engage with other components, such as rubber gaskets, connector pieces, or other components. In certain embodiments, there may be an additional protrusion <NUM> which may form cavities for seals and or desiccant elements when the system is assembled.

<FIG> is a horizontal section view of the existing vertical meeting rail assembly <NUM> of the glazing system <NUM> as illustrated in <FIG> with the addition of two support frames positioned on either side of the mullion cover <NUM>. As illustrated in <FIG>, there is a left side portion of support frame 102c, which includes the side rail member <NUM> and a right side portion of a support frame 102d which includes the side rail member <NUM>. Generally, the side rail member <NUM> and <NUM> may be shaped to allow the formation of a cavity or compartment for seals and other components discussed below. Additionally, the side rail member <NUM> and the side rail member <NUM> may be shaped in cross-section to engage with other components, such as rubber gaskets, connector pieces, or other components, such as a rubber gasket <NUM>.

In one embodiment, as shown in <FIG> and <FIG>, the support frame <NUM> may be attached to the infill panel(s) <NUM> using a peripheral attachment means or mechanism. For instance, a structural adhesive may be applied to surfaces of the top rail member <NUM>, the bottom rail member <NUM>, the first side rail member <NUM>, and the second side rail member <NUM> which will face the infill panel(s) <NUM>. As will be explained below, the rail members forming the support frame <NUM> may then be pressed against the existing infill panel(s) <NUM> which, will in turn, cause the structural adhesive to engage a perimeter area of the infill panel <NUM>. Thus, the support frame <NUM> will then be coupled to a peripheral area of the infill panel <NUM>.

A wide variety of peripheral attachment means (e.g., structural adhesives) may be used to couple the support frame <NUM> to the infill panel <NUM>. In one embodiment, a structural adhesive seal <NUM>, such as Dow Corning® structural silicone sealants, which may be applied in the field to the top, bottom, and side rail members <NUM>, <NUM>, <NUM>, and <NUM>. Additionally, one or more double-sided peripheral adhesive tapes <NUM> may be applied to the top, bottom, and side rails <NUM>, <NUM>, <NUM>, <NUM> in the shop or in the field to define an area for the structural adhesive seal <NUM> and to hold the rails in place as a means for temporary attachment until the structural adhesive seal <NUM> may be fully cured and ready to carry the load of the assembled system.

In one embodiment, one or more of the double-sided peripheral adhesive tapes <NUM> maybe polyisobutylene or butyl glazing tapes for a lower water vapor transmission rate ("WVTR"), and/or structural adhesive tapes for a higher initial load resistance. A rubber gasket <NUM> may be used to cover the exposed side of the adhesive tapes and the top, bottom, and side rails <NUM>, <NUM>, <NUM>, <NUM>.

In an alternate embodiment, as shown in <FIG>, a shop or field-applied double-sided structural adhesive tape <NUM>, such as <NUM>® VHB tapes, may be substituted for the structural adhesive seal <NUM> along with one or all of its associated double-sided adhesive tapes <NUM> in the top, bottom, and side rail members <NUM>, <NUM>, <NUM>, <NUM>, or only in the side rail members <NUM>, <NUM>. It should be noted that the sizes of the structural adhesive elements are exemplary only and not intended to limit the scope of the present disclosure. Typically, their sizes are determined based on case-by-case structural calculations.

Turning back to <FIG> and <FIG>, in certain embodiments, a gap <NUM> may be formed around the periphery of the glazing shield system <NUM>. A portion of the gap <NUM> for the support frame 102a is illustrated as formed between the upper profile member <NUM> and the transom cover <NUM>. A similar portion of the gap <NUM> for the support frame 102b is illustrated as formed between the lower profile member <NUM> and the transom cover <NUM>. The gap <NUM> provides dimensional tolerance and allows for installation, panel movement, and thermal expansion. In one embodiment, the gap <NUM> may be set/defined using standard or custom spacing tools or removable installation caps coupled to the support frame <NUM>. In one embodiment, a dry seal, such as a rubber gasket <NUM>, may be used on the outside periphery of the support frame <NUM> to fill the gap <NUM> and create a rear air-and-water barrier around the periphery of the support frame <NUM>. In an alternate embodiment, a wet seal <NUM> that may be applied in the field after installing the support frame <NUM> may substitute the rubber gasket <NUM> (as shown in <FIG>) and may provide additional structural support. In certain embodiments, the wet seal <NUM> may be a butyl rubber caulk for a lower WVRT. In some embodiments, one or more setting blocks or shims (not shown) may be used under the bottom rail assembly <NUM> for additional structural support.

<FIG> is a partially cut isometric view of an exemplary unitized panel which may be used with the current system <NUM>. The unitized panel <NUM>, which may be pre-assembled at a shop or a fabrication facility, comprises a unit frame <NUM> and an infill panel <NUM>. In certain embodiments, the unit frame <NUM> comprises a top profile member <NUM>, bottom profile member <NUM>, and side profile members <NUM>, <NUM>, as shown in <FIG>. In one embodiment, the unit frame <NUM> (and its profile members) may be made up of an extruded metal, such as aluminum. In an alternate embodiment, the profile members may be made up of an extruded composite or polymer-based material, such as polyvinyl chloride (PVC) or unplasticized polyvinyl chloride (uPVC), for better thermal performance. In such embodiments, an additional metal piece or extrusion may be used with the composite or polymer-based profile members for better adhesive bonding and structural performance.

The infill panel <NUM> may be any type of vision, spandrel, shadowbox, or cladding infill panel. The infill panel <NUM> may be made up of single or composite materials including, but not limited to, glass, polymer-based materials such as acrylic or polycarbonate, or metal such as aluminum. In one embodiment, the infill panel <NUM> may be a monolithic glazing panel of a single or laminated glass of any type or configuration. In another embodiment, the infill panel <NUM> may be an insulating glass unit with double or multi-layers of any type or configuration, including vacuum insulated panels. The infill panel <NUM> can be a clear, semi-transparent, translucent, or opaque infill panel.

In certain embodiments, the infill panel <NUM> may incorporate one or a combination of films and/or coatings of any type including, but not limited to, solar control films, polymer dispersed liquid crystal (PDLC) films, hard (sputtered) or soft (pyrolytic) coatings like metal oxide coatings, low emissivity coatings, electrochromic coatings, thermochromic coatings, photovoltaic coatings and the like.

<FIG> is a vertical section view of the existing horizontal meeting rail assembly <NUM> of the glazing system <NUM> as illustrated in <FIG> with the addition of two unitized panels positioned above and below the transom cover <NUM>. The two unitized panels 104a and 104b are positioned adjacent and are illustrated mated to the support frames 102a and 102b.

<FIG> is also a vertical section view of the existing horizontal meeting rail assembly <NUM> of the glazing system <NUM> as illustrated in <FIG> with the addition of two unitized panels positioned above and below the transom cover <NUM>. The two unitized panels 104a and 104b are positioned adjacent and are illustrated mated to the support frames 102a and 102b. The embodiment illustrated in <FIG> is conceptually similar to the embodiment illustrated in <FIG>, but the embodiment of <FIG> illustrates alternative details which will be discussed below.

As illustrated in <FIG> and <FIG>, there is an upper portion of the unitized panel 104a, which includes the top profile member <NUM>. The top profile member <NUM> is shaped to mate with the interconnecting or anchoring means of the top rail member <NUM>. Specifically, in one embodiment, the top profile member <NUM> includes an inverted hook-like protrusion <NUM> sized and shaped to engage and fit within the hook-like space created by the protrusion <NUM> of the top rail member <NUM>. In addition to interconnecting features, the top profile member <NUM> may be shaped in cross-section to engage with other components, such as rubber gaskets (e.g., rubber gasket <NUM> and rubber gaskets <NUM> of the embodiment illustrated <FIG>), connector pieces, or other components.

Similarly, the bottom profile member <NUM> of the unitized panel 104b may be shaped to mate with the interconnecting or anchoring means of the bottom rail member <NUM>. For example, the bottom profile member <NUM> includes an inverted hook-like protrusion <NUM> sized and shaped to engage and fit within the space created by the hook-like protrusion <NUM> of the bottom rail member <NUM>. In addition to interconnecting features, the bottom profile member <NUM> may be shaped in cross-section to engage with other components, such as rubber gaskets (e.g., rubber gasket <NUM> and rubber gaskets <NUM> of the embodiment illustrated in <FIG>), connector pieces, or other components.

<FIG> is a horizontal section view of the existing vertical meeting rail assembly <NUM> of the glazing system <NUM> as illustrated in <FIG> with the addition of two unitized panel positioned on either side of the mullion cover <NUM>. As illustrated in <FIG>, there is a left side portion of a unitized panel 104c which includes a first side profile member <NUM>, and a right side portion of a unitized panel 104d which includes a second side profile member <NUM>. The first side profile member <NUM> and the second side profile member <NUM> may be shaped in cross-section to engage with other components, such as rubber gaskets (e.g., rubber gasket <NUM>), connector pieces, or other components. Note that when the first side profile member <NUM> is positioned adjacent to the side rail member <NUM>, a cavity or compartment <NUM> may be formed. Similarly, when the second side profile member <NUM> is positioned adjacent to the side rail member <NUM>, a cavity or compartment <NUM> may be formed on the opposing side of the mullion cover <NUM>.

Turning to <FIG>, in one embodiment, the infill panel <NUM> may be structurally glazed to the unit frame <NUM> (e.g., profile members <NUM>, <NUM>, <NUM>, and <NUM>) using a structural adhesive seal <NUM>, as shown in <FIG> and <FIG>, or a structural adhesive tape <NUM>, as shown in <FIG>, along with one or more continuous glazing tapes <NUM> and/or one or more setting blocks (not shown). One or more of the continuous glazing tapes <NUM> may be polyisobutylene or butyl glazing tapes for a lower WVTR. In an alternate embodiment, the infill panel <NUM> may be mechanically-glazed to the unit frame <NUM> using common methods presently known in the art. In one embodiment, the infill panel <NUM> may be a laminated glazing panel with a step between the panes comprising the laminate so that the unitized panel <NUM> would extend to the outside edge of the unit frame <NUM> and have a frameless-look as illustrated in <FIG>. In an alternate embodiment, the unitized panel <NUM> may have an exposed frame edge where the unit frame <NUM> may be exposed or covered with a wet or dry seal.

In one embodiment, a dry seal, such as a rubber gasket <NUM>, may be used on the outside periphery of the unitized panel <NUM> to fill the gap <NUM> and create a front air-and-water barrier around the periphery of the unitized panel <NUM>. The rubber gasket <NUM> may be typically notched around existing drain holes <NUM> (see <FIG> and <FIG>). In certain embodiments, the rubber gasket <NUM> may be mitered at the corners and may be bonded into one piece. In an alternate embodiment, a wet seal, such as butyl rubber caulk, may substitute the rubber gasket <NUM> for a lower WVTR and may be applied around the periphery after mounting the unitized panel <NUM> (without blocking the existing drain holes <NUM>).

In one embodiment, a continuous double-sided adhesive tape <NUM> (see <FIG>) with a low WVTR, such as polyisobutylene or butyl glazing tapes, may be shop or field-applied to the unit frame <NUM> to create a continuous water vapor barrier around the perimeter between the support frame <NUM> and the unitized panel <NUM> once the unitized panel <NUM> is mounted on the support frame <NUM>. Additionally, a wet seal (not shown), such as butyl rubber caulk, may be applied in the shop at the areas where the top, bottom, and side profile members <NUM>, <NUM>, <NUM>, and <NUM> of the unit frame <NUM> meet at the corners for a lower WVTR.

In certain embodiments, the unit frame <NUM> may incorporate a desiccant element <NUM> to help in reducing the possibility of condensation forming on the surfaces adjacent to the newly-formed air gap <NUM>. In one embodiment, the desiccant element <NUM> may be a warm spacer of silicone foam base with desiccant pre-fill and pre-applied side adhesive for bonding, such as Quanex Super Spacers. In certain embodiments, such as the embodiment illustrated in <FIG>, an additional desiccant element <NUM>, such as a metal, composite, or polymer-based spacer filled with a desiccant material like molecular sieve, may be added to the unit frame <NUM> in the shop or in the field using for example a double-sided adhesive tape such as butyl glazing tapes, to further help in removing any residual moisture in the newly-formed air gap <NUM> and increase the overall desiccant capacity in the glazing shield system <NUM>.

The engagement of the hook-like protrusions <NUM> of top and bottom profile members <NUM> and <NUM> with the hook-like protrusions <NUM> of the top and bottom rail members <NUM> and <NUM> prevent the unitized panel <NUM> from moving on the axis that is perpendicular to the plane of the unitized panel <NUM> and from going off the support frame <NUM>. Additionally, the side profile members <NUM>, <NUM> of the unit frame <NUM> may incorporate one or more protrusions <NUM> (see <FIG>). The protrusion(s) <NUM> may have a rectilinear shape for additional static load support or a hook-like shape (see <FIG>) for additional static and dynamic load support.

<FIG> is a section view of one embodiment of a lower portion of the unitized panel <NUM>. In <FIG>, a hook-like protrusion <NUM> is visible extending away from and perpendicular to the side profile member <NUM>. When the unitized panel <NUM> is mounted on the support frame <NUM>, the protrusion(s) <NUM> will go through a corresponding opening <NUM> (see <FIG>) defined in the side rails <NUM>, <NUM> of the support frame <NUM>. Once the unitized panel <NUM> is tucked in place, the hook-like protrusion(s) <NUM> will engage a portion of the support frame <NUM>. Thus, the hook shape allows the unitized panel to be "locked" horizontally in place with respect to the support frame <NUM>.

In other embodiments, the protrusion(s) <NUM> may be of any shape and may simply enter the corresponding opening. For instance, if the opening <NUM> is L-shaped as illustrated in <FIG>, the protrusion(s) <NUM> will initially penetrate the longer, vertical leg, but then be positioned so that it resides in the shorter leg of the opening <NUM> to prevent the unitized panel <NUM> from moving vertically and from going off the support frame <NUM>. In certain embodiments, the top and bottom profile members <NUM>, <NUM> of the unit frame(s) <NUM> may also incorporate a rubber gasket <NUM> (see <FIG>) with a relatively low compression set or a high durometer to further add additional resistance to the independent vertical movement of the unitized panel <NUM>. In an alternate embodiment, a linear spring-like element may substitute the rubber gasket <NUM>. In alternate embodiments, a fastener, a lock handle, or a latch as commonly known in the art, may be used instead or in addition to lock the unitized panel <NUM> in place.

The glazing shield system <NUM> can be mounted on either the exterior or the interior side of an existing glazing system. In certain embodiments, one or more support frames <NUM> may be attached to clean existing infill panels <NUM> of the existing glazing system <NUM>. See for instance, <FIG>, <FIG> and <FIG>. In an alternate embodiment, the support frame <NUM> may be attached to the framework of the existing glazing system. In such an embodiment, structural adhesives would be applied to clean surfaces of a framework surrounding an existing infill panel. In such embodiments, the framework surrounding an existing infill panel can be considered a peripheral area of the infill panel and part of the infill panel itself for purposes of this disclosure and claims.

In certain embodiments, the support frame <NUM> may be installed in pieces or in multiple smaller assemblies that are either assembled on site or pre-assembled in a shop or a fabrication facility as shown in <FIG>. In an alternate embodiment, the support frame <NUM> may be installed in one piece as a unit that is either assembled on site or pre-assembled in a shop or a fabrication facility.

<FIG> is an exploded isometric view of the support frame <NUM> positioned adjacent to an existing infill panel <NUM>. In the embodiment, illustrated in <FIG>, the support frame <NUM> is shown exploded into various components or assemblies and illustrates one method of assembly.

In one embodiment such as illustrated in <FIG>, the support frame <NUM> may be installed in separate smaller assemblies, the top and/or bottom rail assemblies <NUM>, <NUM> may be installed first and the side rail assemblies <NUM>, <NUM> may then be partially installed while allowing the other top or bottom rail assembly <NUM>, <NUM> to be correctly positioned relative to the side rail assemblies <NUM>, <NUM> and be fully installed before completely installing the side rail assemblies <NUM>, <NUM> (i.e., attached to the infill panel <NUM>). In one embodiment, wherein the structural adhesive seal <NUM> is utilized (see <FIG>), the support frame <NUM> may be installed by applying the structural adhesive seal <NUM> to the area that is defined by the double-sided adhesive tapes <NUM>; peeling out the poly-liners off the adhesive tapes <NUM>; and then attaching the support frame <NUM> to the infill panel <NUM> after cleaning and preparing the peripheral area of the infill panel <NUM>-following the recommended instructions by the structural adhesive seal manufacturer- and applying suitable temporary pressure, for instance, about <NUM> PSI or more.

In an alternate embodiment, where the structural adhesive tape <NUM> is utilized (see <FIG>), the support frame <NUM> may be installed by peeling out the poly-liner off the structural adhesive tape <NUM> and then attaching the support frame <NUM> to the infill panel <NUM> after cleaning and preparing the peripheral area of the infill panel <NUM>-following the recommended instructions by the structural adhesive tape manufacturer- and applying suitable temporary pressure, for instance, of <NUM> PSI or more.

In one embodiment, top hook-like connector pieces <NUM> and bottom hook-like connector pieces <NUM> (see <FIG> and <FIG>) may be added to the side rails <NUM>, <NUM> using, for example, a double-sided structural adhesive tape <NUM> to connect the side rail assemblies <NUM>, <NUM> to the top and bottom rail assemblies <NUM>, <NUM> and allow the support frame <NUM> to work as a unit. In one embodiment, a wet seal (not shown, such as butyl rubber caulk, may be applied in the field to the support frame <NUM>-before the side rail assemblies <NUM>, <NUM> are installed and connected with the top and bottom rail assemblies <NUM>, <NUM>-at areas <NUM> (see <FIG>) where the top and bottom rails <NUM>, <NUM> meet the side rails <NUM>, <NUM> for a lower WVTR. In one embodiment, a wet seal <NUM> (see <FIG>) may be applied in the shop or in the field to the top and bottom rails <NUM>, <NUM>-except where the connector pieces <NUM>, <NUM> would fit on the top and bottom rail members <NUM>, <NUM>-to easily guide the installation of the side rail assemblies <NUM>,<NUM> to the right location relative to the top and bottom rail assemblies <NUM> and <NUM>.

An additional installation step is mounting the pre-fabricated unitized panel <NUM> onto the support frame <NUM>, which in certain embodiments, may trap a volume of air and create an insulated air gap <NUM> (see <FIG>, <FIG>, and <FIG>) between the infill panel <NUM> of the existing glazing system <NUM> and the unitized panel <NUM> of the glazing shield system <NUM>. To couple the unitized panel <NUM> to the support frame <NUM>, one or more workers may tuck the unitized panel <NUM> towards the top right corner of the support frame <NUM> and push it towards it until the hook-like protrusions <NUM> of the top and bottom profile members <NUM>, <NUM> of the unitized panel <NUM> stops inside the top and bottom rail members <NUM>, <NUM> of the support frame <NUM> and the protrusions <NUM> stop inside their associated openings <NUM>.

Next, the worker(s) may lower the unitized panel <NUM> until the hook-like protrusions <NUM> of the top and bottom profile members <NUM>, <NUM> of the unitized panel <NUM> rest on and within the space created by the hook-like protrusions <NUM> of the top and bottom rail members <NUM>, <NUM> of the support frame <NUM> and the protrusions <NUM> rest on and possibly hook within the bottom edge of their associated openings <NUM>, allowing the support frame <NUM> to carry the unitized panel <NUM>. The worker(s) may then tuck the unitized panel <NUM> to the worker's left until the protrusions <NUM> hit the edge of their associated openings <NUM> and stop the unitized panel <NUM> from moving further.

An existing façade access system, such as a window washing platform or a building maintenance unit, may be utilized when attaching the support frame and mounting the unitized panel without the need for additional scaffolds or custom installation platforms. In certain embodiments, the unitized panel <NUM> may also incorporate a number of polyethylene poly-liners, wax papers, and/or other polymer-based protective layers that may be removed right before mounting the unitized panel, which may be used to protect the other adhesive side of the double-sided adhesive tape <NUM>; protect the desiccant elements <NUM>, <NUM> from getting saturated with moisture before mounting the unitized panel <NUM>; and keep the face of the infill panel <NUM> that would be adjacent to the air gap <NUM> clean until mounting the unitized panel <NUM>.

In certain embodiments, the fabrication of the top, bottom, and side rail members <NUM>, <NUM>, <NUM>, <NUM> of the support frame <NUM>; the top, bottom and side profile members <NUM>, <NUM>, <NUM>, <NUM> of the unitized panel <NUM>; and the connector pieces <NUM>, <NUM> may be typically performed using an extrusion method. In one embodiment, after the profile members are extruded, the top, bottom, and side rail members <NUM>, <NUM>, <NUM>, <NUM> of the support frame <NUM> may be cut to length using a <NUM>-degree angle while the top, bottom, and side profile members <NUM>, <NUM>, <NUM>, <NUM> of the unit frame <NUM> may be cut to length using a <NUM>-degree angle. The protrusions <NUM> may then be trimmed/cut using saw blades and/or a computer numerical control (CNC) machine, and notches, openings, such as openings <NUM>, <NUM>, etc. may be formed using a CNC machine.

In certain embodiments, the unitized panel <NUM> may be an active, self-sufficient panel able to convert absorbed light into electrical energy, store it in an incorporated energy storage device, and power one or more built-in devices and/or systems in the unitized panel <NUM>, which in turn, may be controlled by the end user, a building automation system, or an energy management system through a built-in control system with power and communication functions including wireless capabilities.

<FIG> is a detailed horizontal section view at an existing vertical rail assembly <NUM> illustrating one embodiment of the system <NUM> incorporating various components of a "smart" window or "smart" system. In the embodiment illustrated in <FIG>, the infill panel <NUM> may be a monolithic glazing panel of two or more panes, such as proximal or outer pane <NUM> and distal or inner pane <NUM>. The panes <NUM> and <NUM> may include glass or polymer-based substrates and may be laminated using one or more interlayers <NUM>, such as Polyvinyl Butyral (PVB). In certain embodiments, the infill panel <NUM> may incorporate one or more photovoltaic (PV) cells or cell systems. As used in this disclosure, the term "cell" may incorporate one or more films and/or coatings known in the industry which essentially operate similar to solar cells. For instance, as used in this disclosure, the term PV cell may include transparent/substantially-clear PV coatings, such as SolarWindow® PV coatings or Ubiquitous Energy® wavelength-selective PV coatings, or it may include a multilayer amalgamation of several layers or coatings to transform light to electrical voltage as is well known in the art. In certain embodiments, the PV cell <NUM> may be applied to one of the panes of the infill panel <NUM>, such as on a distal surface of the outer pane <NUM>.

Additionally, the infill panel <NUM> may incorporate one or more electrochromic (EC) layers or layer systems <NUM>. Used in this disclosure, the term "layer" may include one or more films and/or coating layers, which may be conductive layers that have light transmissivity that is variable in response to an electrical current, such as View Glass® or SageGlass® electrochromic coatings. The EC layer <NUM> may be applied to one of the other panes of the infill panel <NUM>, such as on the proximal surface of the inner pane <NUM>. Additional coatings and/or films may also be incorporated between the layers of the infill panel <NUM> and/or applied on the proximal surface of the outer pane <NUM> or the distal surface of the inner pane <NUM>.

The PV cell(s) <NUM> may incorporate one or more transparent electrodes that connect the photovoltaic coating layer(s) to a control system <NUM> using wire(s) or leads <NUM> that go through one or more notches <NUM> in the side profile members of the unit frame <NUM>, such as profile member <NUM>. Additionally, the EC layer(s) <NUM> may incorporate one or more electrical connections (not shown), such as busbars, that connect the electrochromic coating layer(s) to the control system <NUM> using wire(s) <NUM> that go through one or more notches <NUM> in the side profile members of the unit frame <NUM>, such as side profile member <NUM>.

In one embodiment, the unit frame <NUM> may also incorporate a light source, such as linear light-emitting diode (LED) lighting strip <NUM> that may be connected to the control system <NUM> using wire(s) <NUM> that go through the notches <NUM> in the side profile members of the unit frame <NUM>, such as profile member <NUM>.

In one embodiment, the control system <NUM> and an energy storage device <NUM>, such as a battery, in communication with the control system <NUM> may be attached to the side profile members <NUM>, <NUM> of the unit frame <NUM> using, for example, a double-sided adhesive tape <NUM> and located so that they go through the opening <NUM> and fit inside the cavity <NUM> defined by the side rail member <NUM> of the support frame <NUM> while leaving a tolerance gap for moving/mounting the unitized panel <NUM> on to the support spacer <NUM>.

<FIG> is a functional diagram of one smart embodiment that may be included in the system <NUM>, which includes the control system <NUM>. As illustrated in <FIG>, the control system <NUM> may be in communication with the PV cell(s) <NUM>, the EC layer(s) <NUM>, the LED lighting strip(s) <NUM>, and the energy storage device <NUM>.

<FIG> is a functional diagram of one embodiment of the control system <NUM>. In certain embodiments, the control system <NUM> may include one or more circuit boards, cards, or chips that may incorporate one or more microcontrollers/processors <NUM> that include appropriate logic (in a memory <NUM> - See <FIG>) for performing one or more power and/or communication control functions, possibly combined in one single circuit board, card, or chip. Additionally, the control system <NUM> may include a power management unit <NUM> that direct the electrical energy generated by the PV cell(s) <NUM> to either charge the energy storage device <NUM> for later use and/or directly supply current to control/power built-in electronics, devices, and/or systems in the unitized panel <NUM>, including but not limited to, the control system <NUM>, the EC layer(s) <NUM>, and the LED lighting strip <NUM>.

In certain embodiments, the control system <NUM> may also incorporate boost/DC-DC converters <NUM> to step up the voltage of the direct current (DC) that is provided by the PV cell(s) <NUM> to a suitable level for utilization within the system, which may include a maximum power point tracking (MPPT) to maximize power extraction from the PV cell(s) <NUM> under all conditions. The control system <NUM> may also incorporate a power converter <NUM> to convert a low voltage to the power requirements of the EC layer(s) <NUM> and one or more driver circuits <NUM> to feed the power to the EC layer(s) <NUM>.

In certain embodiments, the control system <NUM> may also incorporate one or more communication units <NUM> that are in communication with the processor(s) <NUM> and are used for receiving and sending commands wirelessly to and from the control system <NUM> and one or more remote controllers <NUM>, such as a user interface and/or a building automation system. A computer-readable medium such as the memory <NUM> in communication with the processor(s) <NUM> may be used to store such commands and to store other system information about the unitized panel <NUM> in a configuration file. In certain embodiments, there may also be a radio frequency identification tag (RFID) incorporating system information in a configuration file. The communications unit(s) <NUM> may incorporate a radio for wireless controls, such as RF and/or IR, as well as wireless communication such as Bluetooth, WiFi, Zigbee, EnOcean and the like to send instructions to the processor(s) <NUM> and to send data out to a building automation system, for example.

The control system <NUM> may also incorporate one or more onboard sensors <NUM>, such as thermal sensors, in communication with the processor(s) <NUM>. Additionally, the control system <NUM> may be in communication with one or more remote and/or frame-incorporated sensors <NUM>, such as optical sensors, through a signal conditioning module <NUM> and/or through the communication circuit(s) <NUM>.

In certain embodiments, output from the remote controller(s) <NUM> or the sensor(s) <NUM> to the control system <NUM> determines a tint level of the EC layer(s) <NUM>, based on various information from the configuration file in the memory <NUM>. The processor(s) <NUM> may then instruct the power management unit <NUM> to apply a voltage and/or current to the EC layer(s) <NUM> to transition to the desired tint level. In certain embodiments, the control system <NUM> may also be configured to have a user interface, for example when automation is not required, so that it can function as an I/O controller for an end user where, for example, a keypad or other user-controlled interface is available to the end user to control the EC layer(s) functions and/or other functions related to other built-in devices/systems in the unitized panel <NUM>.

In yet other embodiments, the control system <NUM> may incorporate one or more wireless power transmitters and/or receivers for wireless power functions, which can be used to power one or more electronic devices and/or systems within the unitized panel <NUM> or transmit power generated by the PV cell(s) <NUM> for use with other devices in close proximity to the unitized panel <NUM>. Wireless power transmission includes, for example but not limited to, induction, resonance induction, radio frequency power transfer, microwave power transfer and laser power transfer. It should be noted that while the embodiments are described as a retrofit system to be used with existing glazing systems, those skilled in the art will appreciate that these embodiments, or the glazing shield parts thereof, may also be provided as integral parts of improved new or replacement glazing systems. For example, the removable unitized panel <NUM> and its associated mounting mechanism may be readily incorporated in the framework of a new glazing system so that it includes a removable, insulated glazing shield to protect and enhance the non-removable primary glazing system.

The abstract of the disclosure is provided for the sole reason of complying with the rules requiring an abstract, which will allow a searcher to quickly ascertain the subject matter of the technical disclosure of any patent issued from this disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Claim 1:
A system (<NUM>) for retrofitting an existing glazing system comprising:
a support frame (<NUM>) comprising:
an upper rail member having a first means for interconnecting,
a lower rail member having a second means for interconnecting,
a first side rail member joining the upper rail member to the lower rail member,
a second side rail member joining the upper rail member to the lower rail member,
a peripheral attachment means for attaching the support frame to an existing infill panel of the existing glazing system,
a unitized panel (<NUM>) removably coupled to the support frame, the unitized panel comprising:
a unit frame (<NUM>) comprising:
a head profile member shaped to mate with the first means for interconnecting,
a sill profile member shaped to mate with the second means for interconnecting,
a first mullion member joining the head profile member to the sill profile member,
a second mullion member joining the head profile member to the sill profile member,
an infill panel (<NUM>) coupled to the unit frame, and
an attachment means for coupling the infill panel to the unit frame.