CA1178771A

CA1178771A - Wall assembly

Info

Publication number: CA1178771A
Application number: CA000430574A
Authority: CA
Inventors: J. Bradley Walsh
Original assignee: Individual
Current assignee: Individual
Priority date: 1983-06-16
Filing date: 1983-06-16
Publication date: 1984-12-04
Also published as: GB2142357B; GB2142357A; GB8415296D0

Abstract

Rogers, Bereskin and Parr CANADA

TITLE: WALL ASSEMBLY

INVENTOR: J. Bradley Walsh ABSTRACT OF THE DISCLOSURE

A wall assembly suitable for use as curtain walling is provided. It has construction panels, suitable for mounting in apertures of a framework or support. The framework can be formed from individual mullions. The construction panel has a frame, and a sheet of material, for example glass. This sheet of material is secured to the frame by a layer of adhesive substance. The frame has surfaces, which extend generally perpendicular to the sheet, for abutting corresponding surfaces of the framework. Both the surfaces of the frame and the framework include complimentary coupling formations, which engage each other when the construction panel is mounted in the aperture. These coupling formations transmit at least part of any load applied to perpendicular to the sheet from the construction panel to the frame.

Description

This invention relates to a wall assembly. This invention more particularly relates to a wall assembly, for use as a curtain wall on a building.
In many buildings, particularly large buildings, it is common to form the main structure of the building from reinforced concrete and then to provide a curtain wall for the exterior faces of the building. Frequently, such curtain walls use a large amount of glass. The glass is mounted to a framework of horizontal and vertical mullions, which themselves are secured to the main structure of the building. For the windows of the building, either single or do-uble panes are used. For portions of the wall which are to be opaque, again glass can be used. Special opaque glasses are made, and the use of such opaque glasses has the advantage that the entire wall surface is formed from similar types of panels, namely glass panels.
The individual glass panels can be secured to the horizontal and vertical mullions by means of elongate clamping members which abutt the outer edge surfaces of the panels and are secured to the mullions. This provides a secure mounting of the glass, but in some designs the fastening elements can be unsightly.
An alternative technique is to mount each glass panel by means of a silicone adhesive substance. This can be used to glue the respective panel directly to the horizontal and vertical mullions. ~his enables a wall to be constructed which has the appearance of being an almost continuous layer of glass.
However, there is a disadvantage in that the silicone adhesive ~.
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has to be applied on the site, and care is necessary to ensure that the panels are secured properly, particularl~ since the silicone adhesive is the only thinq holdina the panels in place.
An alternative construction technique is to provide each glass panel with a individual frame, which is glued to the panel in a factory. In the factory, the panel is placed with its outer face down~ the frame is then positioned on the back of the panel, and the adhesive substance is then applied to secure the two together. The frame is provided with slots, and on site these are engaged with correspondingly shaped vertical mullions. This design has the disadvantage that assembly on site can be difficult. Each panel has to be slid into position between two vertical mullions, and then a horizontal mullion can be placed across the top to secure the panel completely. -It is extremely difficult to replace a complete panel aftercompletion of the building. It may only be possible to replace a pane, by leaving the original frame in place and then a glueing ~ fresh glass panel to that frame. Again, one encounters the problem of ensuring that one has the proper conditions for the silicone adhesive.
Accordingly, the present invention is directed to a wall assembly and to a frame and a construction panel for a wall assembly, which provide for ready assembly of the wall and which enable individual panels to be replaced after construction of a building.
The construction panel of the present invention has a .

frame secured to a sheet of material by a layer of adhesive substance applied to a back surface of the sheet. The frame includes surfaces generally e~tending from the sheet for abutting corresponding surfaces of a support framework or the like. Coupliny formations in these surfaces are provided. In In use, a support framework, for example, formed of horizontal and vertical mullions is provided, and the framework includes other surfaces which have corresponding coupling formations ,~ ~hese otner surfaces bound an aperture in the support framework.
LO The panel can be located in the aperture, with its surfaces abutting the other surfaces of the support framework, and with its coupling formations engaging the coupling formations of the ~upport framework. Preferably, fastening elements, such as screws are provided to secure the wall assembly in position. The ~L5 arrangement is such that the screws need only locate the panel in ; position. Any forces applied perpendicu~ar to the panel, such as wind loads, are transferred to the support framework by means of the coupling formations. Thus, screws perpendicular to the abutting surfaces need not be subjected to any sh~ar loads.
~!0 If any panel should be broken, it can be readily removed, by removing the screws or other fastening elements. The panel can then be pulled out from the exterior of the building. The frame of the panel, the support framework and their coupling formations can be designed to be sufficiently resilient to permit the coupling 2S formations to slide over one another, so that the panel can be removed. A fresh panel can then be similarly inserted, and then secured in position by the screws or other fastening elements. Such 2 ~, procedure not only permits broken panels to be replaced, but also enables the exterior wall of a building to be readily changed. For example, if experience shows that the original panelling of a building does not have required thermal properties the panels can be exchanged for new panels having desired thermal characteristics.
For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which embodiments of the present invention are shown and in which:
Figure 1 shows a horizontal view of a part of a wall assembly according to the present invention;
Figure 2 shows a detail of part of a-framework shown in Figure l; . .
Figure 3 shows a horizontal cross-section through part of a wall assembly according to the present invention;
Figure 4 shows a vertical cross-section of part of the wall assembly, corresponding to Figure 3;

20Figure 5 shows a cross-section through an alternative mullion profile;
Figure 6 shows a detail of the wall assem~ly for accomodating different panel thicknesses.
Referring first to Figure 1, one framework, for 25supporting individual panels, is generally denoted by the reference 1. The framework 1 is shown abutting adjacent frameworks 2 and 3, the framework 2 being located on the left and the framework 3 being located below the framework 1.
Each framework is secured to a concrete floor 4 of the building by means of angle brackets and bolts, which are described below.
The framework 1 defines an aperture 5 for a constructian panel. In this aperture, a construction panel 6 is mounted. The panel comprises a pane of glass 7 and a frame 8 (see figure 3).
A description will now be given of the framework 1, the other framewo~ks being similar to the framework 1. The outer periphery of the framework 1 is defined by a vertical male mullion 10, a vertical female mullion 11, a horizontal male mullion 12 and a horizontal female mullion 13. The vertical mullions 10 and 11 are compliment~ry to one another, as are the horizontal mullions 12 and 13. Thus, the vertical female mullion 11 engages a corresponding vertical male mullion 10 of the framework 2 on the left, whilst the male horizontal mullion 12 engages a female horizontal mullion 13 of the framework 3 below.
Extending across the middle of the framework 1 are two further male and female mullions 14 and 15, which are engaged with one another. These mullions 14 and 15 separate the aperture 5 from a further aperture 16 and are similar to the male and female horizontal mullions 12 and 13 respectively. Extending vertically across the aperture 16 are two members 17, which are secured to the horizontal mullions 12, 15. Each of the members 17 is gener~ly rec~ngular and hollow, and, on an inside face,is provided with ~ '..~, a slot (see Figure 2). Inside the m~æ~ 17 a block 19 is located. At the edge of the concrete floor 4, angle brackets 20 are provided.
Each of these brackets 20 is secured to the floor 4, and can be provided with means for adjusting its position horizontally.
An upright limb of each bracket 20 is provided with two openings for bolts21. The bolts 21 are screwed into threaded bolts in the block 19, to clamp the members 17 against the brackets 20, and thus to secure the framework 1 in position. To mount the framework in position, it is located in position adjacent the previously mounted frameworks 2 and 3, with its mullions 11 and 12 engaging the corresponding mullions 10 and 13 of the frameworks 2 and 3. Then, bolts 21 are passed through the angle brackets 20 and through the slots 18 into the blocks 19 previously provided in the members 17. The vertical, and to some extent the horizontal, position of the framework 1 can then be adjusted ~ince the slots 18 permit relative movement between the framework 1 on the one hand and the bracket 20 and bolts 21 on the other.
Once the framework 1 has been correctly positioned, the bolts 21 are tightened to clamp it in positiOn.
The members 17 are of shallower depth than the mullions to permit them to be set back from a front face of the framework 1. This enables the aperture 16 to be covered by a single construction panel covering the members 17.
Figure 3 shows details of the two vertical mullions 10 and 11. Each of the mullions 10, 11 is generally U-shaped so that together they form a generally rectangular section member. The mullions 10 and 11 are extruded from aluminum.
The female vertical mullion 10 is provided with internal grooves 25 extending along its length. The male vertical mullion 11 is provided with inset flanges 26, adapted to engage the female mullion 10. The flanges 26 include inclined portions 27, to aid coupling of the two mullions 10, 11, and elongate ridges or projections 28. These ridges 28 engage the grooves 25, to couple the two mullions 10, 11 together. Each of the vertical mullions 10, 11 includes an extension 2g, which has a flat surface 30 for coupling to the frame 8. Also, each of the extensions 29 is extruded with an elongate slot 31 having serrated sides for engaging threads of a screw or bolt.
The horizontal mullions 12, 13 are similar to the vertical mullions 10, 11. Again, they are extruded from aluminum. Figure 4 shows a section through the horizontal mullions 14, 15 which are of similar section to the horizontal mullions, 12, 13 around the periphery of the framework 1. The male horizontal mullion 14 is a U-shaped channel section with two inset extension flanges 35. Each of these flanges 35 includes an inclined extension 36, to aid coupling of the two mullions, 14, 15. The horizontal female mullion 15 is a simple U-shaped channel section, which slidingly receives the flanges 35. This arrangement of the horizontal mullions, permits considerable vertical adjustment between adjacent frameworks. ~ach of the horizontal mullions 14, 15 includes a respective extension 37. Again, ~hese extensions 37 , r`,.~1 _ ~ _ - s provide coupling surfaces 38 for coupling to a frame 8 of a construction panel. Each of the extensions 37 includes an elongate slot 39, which has serrated edges. Screws or bolts can be screwed into this slot 39. To permit the horizontal mullions to be secured to the vertical mullions, the horizontal mullions are provided with elongate generally rounded slots 40, extending along their length. The vertical mullions can then be provided with holes through which screws 41 can be passed and screwed into the slots 40, as shown in Figure 3.
Turning to the construction of the construction panels 6, the frames 8 are secured to the sheet 7 of glazing or other material by a silicone adhesive substance applied in the factory.
To assemble each panel 6, the sheet 7 is placed horizontally with its outer face down. Then, the frame 8 is assembled on the back of the sheet 7. The frame 8 is provided with a resilient spacer gasket 60, which ensures a uniform and constant spacing between the frame 8 and the sheet 7. Then, a silicone application gun or other device is run around the edge of the panel 7 to apply a silicone adhesive substance 61 in the space between the sheet 7 and the frame 8. This silicone adhesive substance 61 secures the frame 8 to the sheet 7. By assembling the panel 6 in this manner in a factory, it can be ensured that the correct conditions regarding cleanliness and other factors are obtained for proper adhesion of the silicone adhesive 61.
The frame 8 is formed from four elongate elements 65 formed by extrusion from aluminum. Each element 65 is of generally T-shaped cross-section. It has a first flange 66 which provides a coupling surface 67 for abutting a respective surface 30 or 38 of a mullion. The flanges 66 ex~end from second flanges 68. The second flanges 68 are generally parallel with the sheet 7, and include an inverted T-shape groove, for receiving a corresponding projection of the spacer gasket 60.
A free edge or extension 70 of the first flange 66 is formed perpendicular to the main part of the first flange 66, so as to define a channel. All these channels face towards the centre of the frame 8.
The surfaces 67 of the first flanges 66 are provided with a serrated portion 71. This portion 71 is formed by a series of adjacent narrow triangular grooves. The coupling surface 30 or 3B of the corresponding mullion is provided with a corresponding serrated portion 72, which if formed by a series of narrow projections of similar triangular section. These serrated portions form coupling formations engaging one another.
Screws 73 pass through openings in the first flanges located opposite the slots 31 or 39, into which they are screwed. The screws 73 hold the elements 65 to their respective mullion extensions 29 and 37. Any load normal to the sheet 7, such as a wind load, is then transmitted to the mullions by the serrated portions 71, 72, so that the screws 73 are not subject to any shear stress. The screws 73 serve only to locate the elements 65 and r ~;

are only subject to tensile stresses. To cover the screws 73, a cover strip 74 is provided. The strip 74 has two securing ribs 75, which engage corresponding ribs 76 of an associated elongate element 65.
In use, after a framework 1 has been positioned and secured in its correct position, the individual construction panels 6 can be mounted on it. As previously mentioned, the construction panels 6 are assembled in a factory. The panels 6 and the mullions are sufficiently resilient to permit the 10 serrated portions 71 and 72 to slide over one another. The resiliency can be provided mainly by the silicone adhesive 61, although, depending on the design, the sheet 7, elements of the frame 8, and the mullions can contribute to the resiliency. Thus, each construction panel 6 can be inserted in an appropriate 15 aperture in a framework. The panel 6 is pushed into its aperture until the second flanges 68 come up against the extensions 29 and 37 of the mullions. Then, the screws 73 are screwed into the serrated slots 31 and 39, to secure the frame 8, and thus the whole panel 6, in position. The cover 20 strip 74 can then be clipped into position to provide a clean attractive interior finish.
The wall assembly has the advantage that the frameworks can be assembled separately from the construction panels.
Consequently, the panels can be assembled in a factory, where 25 the proper and particular conditions necessary for the silicone adhesive substance 61 can be ensured. The panels can be transp~rted in a state reac'y for simple on site assembly with the mullions.
Further, the wall assembly permits ready replacement of the panel. The ~c~

~ ~ s panel 6 can be inserted into a respective framework 1, either before or after the framework is positioned. Assembly before enables the panel 6 to be fitted on the ground or in a factory, so that on site it is simply a matter of fitting all the S frameworks to a structure.
Whilst the above discussion has primarily been directed to a construction panel 6 having a sheet of glass, the technique is equally applicable to construction panels using other materials. For the aperture 5 in the framework 1, a 10 construction panel 6 having a sheet of glass would be used.
However, for the aperture 16 below the aperture 5, an opaque construction panel would normally be used. Such a panel could either be formed from a glass which is opaque or coated with an opaque substance, or from, for example, a sheet metal. Such 15 an opaque construction panel would be mounted in exactly the same manner as a transparent or glazing panel. The members 17 are set back from the face o~ the framework 1, so that the panel could cover the whole of the aperture 16. The opaque panel would then hide the supporting members 17.
Once all the construction panels 6 have been assembled into their respective framework, seals can be made between adjacent panels 6. As shown in figures 3 and 4, between adjacent panels 6, a strip of resilient material 80 can be inserted so that it is iust inside the outer surface of the panels 6. Then, the strip 80 2r and the panel 6 can be sealed by a silicone weather seal applied from the outside as indicated at 81. 1'he strip B0 and the silicone weather seal 81 should be resistant to local weather conditions and able to absorb required amount of expansion and contraction.
Figure 5 shows an alternative embodiment for the mullions. It is particularly applicable to vertical mullions. Here, two symmetrical mullions 90 and 91 are provided. They have respective extension 92 and 93, which are similar to the extensions of the previously described mullions. To join together each of the mullions 90 and 91, they are each provided with internal grooves 94 and 95. A connection member 96 is generally I-shaped, with projections 97, adapted to engage these grooves 94 and 95. This construction is particularly useful where the wall of a building might include various angles other than right angles. It enables a variety of mullion members, like the mullions 90, 91 to be provided which accomodate these various different angles, without having to be concerned about providing appropriate male or female mullion members. Thus, for a wall which turns through 60 at a corner, one could provide two symmetrical mullions, which are each effectively at an angle of 30 to the connectior, member 96. It will be appreciated that the use of one of this type of mullion with one of the mullions 90, 91 would produce an angle of 30.
Figure 6 shows an arrangement, for accomodating sheets 7 of different thicknesses. It shows a similar cross-section to that shown in figure 3, and like parts in figure 6 are given the saie reference numerals as those in figure 3. On the left-hand side of figure 6, there is a panel 100 which comprises two panes of glass 101 which are joined together at a preset spacins by a silicone adhesive substance 102. As for the panel 7 shown in figure 3, this double glazed sheet 100 is secured to a frame 8 formed from the previously described elongate elements 65. Again, gaskets 60 and adhesive substance 61 are used. Since the panel 100 is double glazed, its outer surface is spaced further from the mullions 10, 11. On the right-hand side of figure 6, a panel 105 having a single sheet of glass 106 is shown. To ensure that this panel 105 is flush with the panel 100, its frame 107 is formed from elongate elements 108 of different profile from the elongate element 65. The elements 108 have a longer first flange 109, although the second flange 110 is of similar dimensions to that previously described. Again, first flange 109 includes an extension in order to form a channel facing towards the centre of the frame 107. Extending from the first flange 109 is a third flange 111. On the three flanges 109, 110, and 111 securing ribs or projections 112 are provided, which engage corresponding securing ribs or projections 113 of a cover strip 114. The longer first flange 109, ensures that the two panels 100 and 105 are flush at their outer surfaces, so that the sealing strip 80 and silicone weather seal 81 can be applied as before. This type of construction is particularly applicable to the two panels that might be located in the aperture 5 and 16 of the framework 1 and other frameworks. In the aperture 5, the panel will frequently be a double glazed panel, whereas the aperture 16 will frequently be covered by a panel having a single sheet of opa~ue glass and insulation behind the glass.
The internal arrangement of the elem,ents 65 and cover strips 7~ hides the joints between the elements 65. Consequently, as regards internal appearance, care does not have to be taken for the joints between the elements 65. The elements 65 need not be mitred, but can be simply cut and arranged so that they just touch at their corners.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY OR
PRIVILEGE IS CLAIMED ARE AS FOLLOWS:

1. A frame, capable of being secured to a sheet of material by a layer of adhesive substance, the frame including surfaces for abutting corresponding surfaces of a support, which surfaces, in use, extend from such a sheet, and coupling formations in those surfaces for engagement with corresponding coupling formations of an aperture of a support, whereby, in use, a panel including said frame and a sheet of material is secured in an aperture of a support and at least part of any load applied to that sheet is transmitted to the support through the coupling formations.

2. A construction panel for location in an aperture in a support, the construction panel comprising: a frame as claimed in Claim l; a sheet of material; and a layer of adhesive substance securing the frame to the back surface of the sheet.

3. A construction panel as claimed in Claim 2, which includes openings in the frame for fastening elements, to enable fastening elements, in use, to secure the construction panel in a support to maintain its coupling formations in engagement with corresponding coupling formations of the support, so that at least part of any load applied to that sheet is transmitted to the support through the coupling formations.

4. A construction panel as claimed in Claim 2, which includes a spacer gasket disposed between and contacting the frame and the sheet of material, the layer of adhesive substance being disposed adjacent the spacer gasket.

5. A construction panel as claimed in Claim 4, wherein the frame includes a groove, in which the spacer gasket is mounted.

6. A construction panel as claimed in Claim 2, wherein the frame includes first flanges extending perpendicular to the sheet, and wherein said surfaces and said coupling formations of the frame are provided on one side of the first flanges.

7. A construction panel as claimed in Claim 6, wherein the frame comprises elements defining a T-shape cross-section, each element having a second flange, with a first face to which the sheet of material is secured by the adhesive substance, said first flange extending perpendicularly from a second face of said second flange.

8. A construction panel as claimed in Claim 7, wherein said surfaces and said coupling formations are provided on faces of the first flanges facing out from the frame.

9. A construction panel as claimed in Claim 8, wherein the edges of the first flanges include extensions, extending parallel to the second flanges towards a centre of the frame, to define inwardly facing channels between the first and second flanges.

10. A construction panel as claimed in Claim 9, wherein the channels are provided with cover strips and the first flanges are provided with openings for fastening elements, so that, in use, the cover strips cover heads of fastening elements located in those openings.

11. A construction panel as claimed in Claim 2,7 or 10, wherein the coupling formations comprise elongate projections of triangular cross-section, which between them define channels of triangular cross-section for receiving corresponding triangular projections of a support.

12. A wall assembly comprising:
a support framework, which comprises horizontal and vertical mullions defining an aperture, each of the mullions having a first surface bounding the aperture, which first surfaces are provided with first coupling formations; and a construction panel for location in the aperture in the support framework, which construction panel comprises:
a sheet of material;
a layer of adhesive substance on the back surface of the sheet;
and a frame secured to the sheet by the layer of adhesive substance, which frame includes second surfaces generally perpendicular to the sheet for abutting the first surfaces of the support framework, and second coupling formations in those second surfaces, corresponding to the first coupling formations of the support framework, and for engagement therewith, to transmit, in use, at least part of any load applied perpendicular to the sheet to the support framework.

13. A wall assembly as claimed in claim 12, wherein the aperture is rectangular and the first and second surfaces are planar.

14. A wall assembly as claimed in Claim 13, wherein the support framework comprises a male vertical mullion, a female vertical mullion, a horizontal male mullion and a horizontal female mullion, which mullions are secured together to form a rectangular framework and which include engagement portions for engagement with respective female or male vertical mullions or female or male horizontal mullions of an adjacent framework.

15. A wall assembly as claimed in Claim 14, wherein the female vertical mullion comprises a channel-section member having a back and sides extending from the back to define the channel-section, with inwardly facing grooves being provided at extremities of the sides, and the male vertical mullion member is a channel-section member which includes extensions adapted to slidingly engage such a female vertical mullion and projections for engagement with the grooves of such a female vertical mullion.

16. A wall assembly as claimed in Claim 15, wherein the female horizontal mullion comprises a channel-section member, and the male horizontal mullion is a channel-section member which includes extensions adapted to slidingly engage such a female horizontal mullion.

17. A wall assembly as claimed in Claim 14, wherein each of the mullions includes an extension which is provided with the first surface and the first coupling formation of that mullion.

18. A wall assembly is claimed in Claim 17, wherein the extensions include elongate slots having serrated sides for engaging screw threads, and the frame of the construction panel is provided with openings for screws, whereby, with the construction panel located in the aperture and with screws engaged with the serrated sides of the elongate slots, the frame of the construction panel is secured to the support framework by screws passed through those openings.

19. A wall assembly as claimed in Claim 18, wherein the frame includes first flanges extending perpendicular to the sheet, and wherein said second surfaces and said second coupling formations of the frame are provided on one side of the first flanges facing out from the frame.

20. A wall assembly as claimed in Claim 19, wherein the frame comprises elements defining a T-shape cross-section, each element having a second flange, with a first face to which the sheet of material is secured by the adhesive substance, said first flange extending perpendicularly from a second face of said second flange.

21. A wall assembly as claimed in Claim 20, wherein the edges of the first flanges include extensions, extending parallel to the second flanges towards a centre of the frame, to define inwardly facing channels between the first and second flanges.

22. A wall assembly as claimed in Claim 21, wherein the channels are provided with cover strips and the first flanges are provided with said openings for fastening elements, so that, in use, the cover strips cover heads of fastening elements located in those openings.

23. A wall assembly as claimed in Claim 12,14, or 20, each of first and second coupling formations comprise elongate projections of triangular cross-section, which between them define channels of triangular cross-section for receiving the triangular projections of the other coupling formation.

24. A wall assembly comprising:
a support framework, which comprises horizontal and vertical mullions defining an aperture, each of the mullions having a first surface bounding the aperture, which first surfaces are provided with first coupling formations; and a frame, capable of being secured to a sheet of material by a layer of adhesive substance, which frame includes second surfaces for abutting the first surfaces of the framework, which second surfaces, in use, are generally perpendicular to such a sheet of material, and second coupling formations in those second surfaces, corresponding to the first coupling surfaces, and for engagement therewith, to transmit, in use, at least part of any load applied perpendicular to the sheet secured to the frame.