Static structures (e.g. – buildings) – Multiroom or level – Curtain-wall; i.e. – panel attached outside floor or beam
Reexamination Certificate
2001-06-26
2004-06-15
Safavi, Michael (Department: 3673)
Static structures (e.g., buildings)
Multiroom or level
Curtain-wall; i.e., panel attached outside floor or beam
C052S509000, C052S512000
Reexamination Certificate
active
06748709
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to building exteriors, and interior wall and ceiling covering using curtain wall systems; said systems having box top shaped composite panels hung on the exterior building sheathing or other framework.
2. Background of the Invention
There are two basic types of systems for the curtain wall aluminum composite material (ACM) market. They are a wet and a dry system. A wet system uses a sealant as its primary seal against moisture. A dry system uses a gasket as its primary seal against moisture.
Most patented curtain wall systems pertain to flat glass panel type curtain wall panels. A brief summary of this flat glass panel support structure art follows below.
U.S. Pat. No. 3,548,558 (1970) to Grossman discloses a mullion system (vertical members between window lights) for a curtain wall exterior. An anchor
101
supports a plate which supports a mullion column having segments
107
.
U.S. Pat. No. 3,978,629 (1976) to Echols Sr. discloses a glass panel thermal barrier vertical mullion. Each mullion has an exterior member with a track for maintenance conveyances and has an interior metal member, and has a insulating foam layer therebetween.
U.S. Pat. No. 4,015,390 (1977) to Howorth discloses a glazing structure for a glass panel/curtain wall building.
U.S. Pat. No. 4,121,396 (1978) to Oogami et al. discloses a curtain wall frame structure having channel crossings with four integral legs and backup bars.
U.S. Pat. No. 4,418,506 (1983) to Weber et al. discloses a curtain wall frame structure adding a insulating separator (56) and an insulated bolt to a known frame structure for insulation.
U.S. Pat. No. 4,471,584 (1984) to Dietrich discloses a skylight system with a unique support structure to support a curtain wall flat.
U.S. Pat. No. 4,841,700 (1989) to Matthews discloses a two-piece mullion frame for reducing the face dimension of an aluminum frame.
U.S. Pat. No. 4,996,809 (1991) to Beard discloses a flat panel skylight support frame having built in condensate gutters.
U.S. Pat. No. 5,065,557 (1991) to Laplante et al. discloses a dry gasket seal frame structure for a curtain wall which uses a flat curtain wall panel having inner and outer panel faces, and a spaced apart vertical edge therebetween. A panel can be replaced without having to dismantle any portion of the curtain wall other than the damaged panel.
U.S. Pat. No. 5,199,236 (1993) to Allen discloses a flush appearance glass panel frame structure.
U.S. Pat. No. 5,493,831 (1996) to Jansson discloses a glass panel building support frame presenting a sealed glaze edge between the glass panels.
As Laplante et al. teaches it is advantageous to be able to replace a damaged curtain wall panel using a dry seal, and further advantageous to be able to leave the horizontal and vertical support channels in place for the replacement. The present invention meets these needs in a dry ACM system.
One patented ACM system is U.S. Pat. No. 4,344,267 (1982) to Sukolics which discloses a curtain wall frame structure which allows thermal expansion of the panels to be absorbed by the joints. A vertical channel has a pair of pivotable arms to receive the sides of adjoining panels. In the present invention the exact same ACM may be used. Sukolics requires that a sheathing be installed over the support studs of the building. Then Sukolics' thin and relatively weak, non-structural mullions and horizontal supports can be mounted in a non-sequential (also called non-directional) fashion. This non-sequential erection fashion is preferred over sequential systems. Sequential systems require starting construction at the bottom of a building and progressing left to right, one row at a time, building one row on top of a lower row. Sukolics enables wall construction from the top down which is how rain hits the building during construction. Therefore, using Sukolics' system a builder can erect the frame, complete the roof, then construct the curtain walls from the top down to minimize rain damage to the exposed sheathing of the building.
The present invention provides the same non-sequential method for construction; additionally adding structural mullions and horizontal supports thereby allowing direct fastening to the frame and eliminating the sheathing if desired.
The present invention provides for thermal expansion by means of using floating curtain wall members which expand and contract in their mounting tracks located in the vertical mullions and horizontal supports.
Another prior art reference is a patent pending curtain wall apparatus trademarked RRD200™ by Elward Systems Corporation of Denver, Colo. A combination horizontal support and perimeter extrusion (corner brace) is used, made of aluminum. The top and one side of the curtain wall is firmly bolted to the building. Thus, no “flotation” of the curtain wall exists on an X-Y frame structure as is the case in the present invention. Flotation reduces stresses on the curtain wall panels during thermal and/or stresses on the curtain wall panels setting movement of the building.
Panel installation begins at the bottom with panels inter-leaving at the sides utilizing “male/female” joinery working left to right. Installation continues by stacking the next row on top of the first row and continuing the left to right sequence. Therefore, an individual panel cannot be removed from the center of the wall without removing adjacent panels.
While it is basically a “dry” system because of the use of wiper gaskets, exposed sealant is used in the 4-way intersections due to the male/female differences of the perimeter extrusions.
Rout and return and curtain face support is provided by the perimeter extrusions. The ACM panels are fabricated utilizing known rout and return methodology. The various perimeter extrusions for the curtain wall panels are four different extrusions making the panel “handed”. The present invention uses panels which are symmetrical, facilitating installation.
The system does include a gutter, but it is not continuous and not part of a sub-system, and the gutter only exists on the horizontal member. Weep holes in the horizontal member allow water to flow out and over the curtain wall panels. No integrated X-Y gutter system exists.
The system requires 16-guage (non-standard) studs at precise locations for vertical attachment to the structure, thereby greatly adding to the building cost compared to the present invention. The system does not allow for a “jointless” appearance because it doesn't have a face cap that can be flushed or recessed from the face of the panel. The system does not allow for multiple “joint” colors.
Perimeter extrusions are not the same depth, thus requiring complex shimming; sequential, non-subsystem installation does not allow for integrated three dimensional panels to be incorporated within the system (i.e. signage or column covers, or accent bands that are not flat). The system does not allow for three dimensional joints like a rounded bullnose that would protrude away from the panel.
Another prior art system, shown in
FIGS. 1-3
, is the Miller-Clapperton MCP System 200-D™ (referred to herein as “the MCP system”). The MCP system employs panels made of aluminum composite material (ACM)
1000
as components of an exterior curtain wall or facade of a building. As shown in the vertical sectional view of
FIG. 2
, a horizontal attachment support
30
′ is screwed into sheathing, such as plywood, or through non-structural sheathing, such as gypsum board, into structural building members using structural screws
70
′. Vertical corner clips
3
′ and
40
′ are used to attach the panel
1000
to the horizontal attachment support
30
′. The clips
3
′ and
40
′ attach only to the return leg
22
of panel (i.e., the portion of the panel that is folded 90-degrees after a rout is performed so as to be perpendicular to the face
23
) and provide no support to the face
23
of the panel. Raised positive return attachment rivets
9
′ are used to at
Riddell Paul A.
Riddell Richard A.
Sherman Steven S.
Diversified Panel Systems, Inc.
Fitzpatrick ,Cella, Harper & Scinto
Safavi Michael
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