EP3371387B1

EP3371387B1 - Curtain wall mullions, transoms and systems

Info

Publication number: EP3371387B1
Application number: EP16863054.9A
Authority: EP
Inventors: Todd Frederick
Original assignee: Fremarq Innovations Inc
Current assignee: Fremarq Innovations Inc
Priority date: 2015-11-04
Filing date: 2016-11-04
Publication date: 2024-09-11
Anticipated expiration: 2036-11-04
Also published as: EP3371387A4; EP3371387C0; EP3371387A1; WO2017079578A1

Description

There are curtain wall systems or frameworks in which glazing or other panels are fitted. Curtain walls typically comprise a grid-like framework usually made of aluminum profiled members arranged with transoms (i.e., structures that typically run horizontally) and mullions (i.e., structures that typically run vertically). Glazing or window panels and non-transparent panels may be secured against the transoms and mullions. The framing is attached to a building structure.
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.
US2015/0284951 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 1. The invention also relates to a method of manufacture thereof as defined by appended Claim 12.
Embodiments of the invention are defined in the dependent claims.
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.

BRIEF DESCRIPTION OF THE DRAWINGS

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:

Figure 1 is a front view of a cell of a curtain wall system.
Figure 2 is a sectional view of a mullion along line 2-2 of Figure 1.
Figure 3A is a sectional view of a transom along line 3-3 of Figure 1.
Figure 3B is a sectional view of a transom along line 3-3 of an alternative aspect of Figure 1.
Figure 3C is a sectional view of a transom along line 3-3 of an alternative aspect of Figure 1.
Figure 3D is a sectional view of a transom positioned along a bottom wall of an alternative aspect of Figure 1.
Figure 4 is a sectional view of a mullion along line 2-2 of Figure 1 and involving use of aluminum.
Figure 5 is a sectional view of a transom along line 3-3 of Figure 1 and involving use of aluminum.
Figure 6 is a sectional view of a mullion along line 2-2 of Figure 1.
Figure 7 is a sectional view of a transom along line 3-3 of Figure 1.
Figure 8 is a sectional view of a mullion along line 2-2 of Figure 1.
Figure 9 is a sectional view of a mullion along line 2-2 of Figure 1.
Figure 10 is a sectional view of a mullion positioned along an end wall of Figure 1.
Figure 11 is a section view of a transom according to some embodiments of the claimed invention.
Figure 12 is a sectional view of a transom according to some further embodiments of the claimed invention.
Figure 13 is a section view of a mullion according to some further embodiments of the claimed invention.
Figure 14 is a section view of a mullion according to some further embodiments of the claimed invention.
Figure 15 is a section view of a mullion according to some further embodiments of the claimed invention.
Figure 16 is a section view of a mullion according to aspects of the invention.
Figure 17 is a section view of a transom according to aspects of the invention.

Figures 1 - 10 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.

DETAILED DESCRIPTION OF THE INVENTION

Figure 1 is a front view of a cell 20 of a curtain wall system 22 . System 22 is shown in partial (and panels are not shown). It may be appreciated that multiple cells 20 may comprise system 22. Figure 2 is a sectional view of a mullion 24 of cell 20. Figure 3 is a sectional view of a transom 26 of cell 20. A similar transom 26' is positioned generally parallel with transom 26. A similar mullion 24' is positioned generally parallel with mullion 24. Together mullions 24, 24' and transoms 26, 26' comprise a single cell 20 of curtain wall system 22. It may be appreciated that mullions 24 and transoms 26 also comprise additional cells 20' or components of cells 20' of system 22. It may be appreciated that panels such as windows, glass, or plates or other objects may be inserted within a cell 20 to cover or span the space, light or opening created by mullions 24 and transoms 26.
As shown in Figure 2, mullion 24 includes a first mullion segment 30. In some embodiments mullion 24 includes a second mullion segment 32 and a third mullion segment 34. Mullion segments 30, 32 and 34 form a mullion 24 and define a mullion cavity 29. In some embodiments mullion 24 is made of steel. Particularly, segments 30, 32 and 34 may be made of steel. In one example, segments 30, 32 and 34 may be formed by bending 12 gage steel sheets. In one example mullion 24 includes a polymer component 40 which is bonded to mullion 24. Polymer component 40 is formed of a thermally insulating material. In one example polymer component 40 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 40 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 40 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 40 which may also include an external coating or coatings. Polymer component 40 thus has favorable insulating features. In one example involving steel structural segments 30, 32 and 34, polymer component 40 fills a gap that would otherwise lead from outer side 25 to cavity 29.
In one example polymer component 40 is bonded to mullion 24 with an adhesive. A variety of bonding ingredients and techniques may be used to secure polymer component 40 to mullion 24. As shown in one example, polymer component 40 includes an interlock 42 which is configured to receive tail 31 of first mullion segment 30. Tail 31 may be both friction fit within interlock 42 and also bonded within interlock 42 with an adhesive and/or bonding treatments. In one example interlock 42 is a gap defined by polymer component 40. Polymer component 40 may include a lip 43 which in part defines interlock 42 as shown. Polymer component 40 also includes a first arm 44 having a tail-contact surface 45 which is bonded to the outside surface of tail 31. In one example, tail contact surface 45 covers the entire area of the outside surface of tail 31. In this manner tail 31 is not exposed to the outside element which would otherwise tend to corrode or deteriorate tail 31. Polymer component 40 also includes a second arm 46 having a tail contact surface 47 which in one example may be bonded to the outside surface of tail 33 of third mullion segment 34. In one example tail contact surface 47 may cover the entirety of the outside surface of tail 33. It may be appreciated that contact surface 47 may also cover less than the entirety of the outside surface of tail 33. Polymer component 40 may also include a further lip 48 configured to adhere to tail 33. In further examples arm 46 may loosely fit against tail 33 (i.e., not be bonded) so that arm 46 may slide with respect to tail 33. Likewise, lip 48 may also be a loose fit against tail 33. It may be appreciated that alternative configurations of polymer component 40 may be used to assist in adhering polymer component 40 to mullion 24 (whether adhering to segment 30, 32 or 34). Polymer component 40 is configured to adhere to mullion 24 while also having a stem portion 80 extending between or into a gap or pocket defined in part by panels 50, 50'. A fastener 39 may insert through a pressure plate 36 and into the stem to secure panels 50, 50' in position. Seals 60, 60 may be positioned between pressure plate 36 and panel frame 52. A cover plate 38 may be positioned to cover pressure plate 36. It may be appreciated that panel 50 may be positioned within cell 20 while panel 50' may be positioned within an adjacent cell 20'.
In a further example polymer component 40 includes a seal receiver 49 configured to receive a seal 60. In one example seal receiver is defined by seal fingers 41. Seal 60 is configured to insert into seal receiver 49 and between first arm 44 and panel frame 52. Seal 60 may fiction fit to panel frame 52 and may also be bonded to panel frame 52. Seal 60 may be of a conventional variety used in curtain wall systems. Seal 60 may also include a wrap segment 62 to partially cover an edge of first arm 44. In a further example polymer component 40 includes a further seal receiver 49 positioned at or defined by second arm 46. In one example seal receiver 49 may be configured to receive a seal 66 configured to interact with a shoulder 70 described below. In one example seal 66 is positioned between second mullion segment 32 and third mullion segment 34.
As shown in Figure 2 mullion 24 includes a shoulder 70 connected to second mullion segment 32. In one example shoulder 70 includes an interlock 42'. Interlock 42' is configured to receive tail 35 of segment 32. Tail 35 may friction fit within interlock 42' and/or be bonded to shoulder 70 within interlock 42'. Shoulder 70 is made from the same or similar material as is polymer component 40 described above. In one example shoulder 70 abuts polymer component 40. A sealant 64 may be applied where shoulder 70 meets polymer component 40. In a further example shoulder 70 includes a seal receiver 49'. Receiver 49' is configured to receive a seal 60. In one example seal receiver 49' is defined by seal fingers 41. Seal 60 is configured to insert into seal receiver 49' and between shoulder 70 and panel frame 52. Seal 60 may friction fit to panel frame 52. Seal 60 may be of a conventional variety used in curtain wall systems. Panel frame 52 may also be secured to seal 60 with an adhesive. Seal 60 may also include a wrap segment 62 to partially cover an edge of shoulder 70. In a further example shoulder 70 may be configured without elbow 71 (i.e., elbow extends from shoulder 70 at line "e" as shown in Figure 2). Tail 35 may extend further toward tail 31 to lessen a gap there between. Shoulder 70 may friction fit or interlock and/or bond to tail 35.
It may be appreciated that polymer component 40 and shoulder 70 combine to cover the entirety of the outer side 25 of mullion 24. Particularly, polymer component 40 and shoulder 70 are configured such that no portion of mullion 24 is exposed to outer side 25, nor is any segment of mullion 24 in communication with the panels 50, 50' or the pocket 28 between panels 50, 50'. Maintaining the segments of mullion 24 in isolation from the outside atmosphere improves the insulating characteristics of system 22.
As shown, mullion 24 is a composite structure made of steel segments 30, 32, 34 to which the fiberglass items, such as polymer component 40 and shoulder 70 are bonded or laminated. Polymer component 40 and shoulder 70 are configured to remain connected to mullion 24. In one example polymer component 40 and shoulder 70 are continuous in that they span the length of mullion 24.
As shown in Figure 3A, transom 26 (i.e., a horizontally oriented element of cell 20) includes polymer component 140 which is made of material that is the same or similar to the material used to make polymer component 40 referenced above. Polymer component 140 includes a first arm 144 having a transom contact surface 145 and a second arm 146 having a transom contact surface 147. In one example component 140 is bonded to transom 26 at least at contact surfaces 145, 147. Particularly, first arm 144 and second arm 146 may be bonded with an adhesive and other bonding techniques to transom wall 130. Wall 130 is formed of metal and in one example is formed of steel and in one example is bent into configuration.
As shown in Figure 3A, wall 130 includes receiving arm 131, 131'. In one example arm 131 is integrally connected to wall 130 and is configured to receive contact surface 145. Receiving arm 131 may be bent into position as shown for instance in Figure 3 and then welded to transom plate 58 at weld 56. In one example receiving arm 131 leads to receiving hand 132 and hand 132 is in turn welded to transom plate 58 with weld 56. It may be appreciated that hand 1 32' may be oriented parallel or at least substantially parallel with hand 132. As such, hand 132 and hand 132' are opposing walls. Polymer component 140 further includes fingers 141a, 141b configured to bond with wall 130. In one example finger 141a is bonded to hand 132 and finger 141b is bonded to hand 132'. An adhesive may be applied between polymer component 140 and wall 130 to securely bond component 140 along an entirety of the exterior surface of arm 131 and continuing about the curve 133 and along hand 132. Likewise, an adhesive may be applied to securely bond component 140 along an entirety of the exterior surface of arm 131' and continuing about the curve and along hand 132'. It may be appreciated that the combination of adhesive and the structural matching arrangement of fingers 141 combine to provide a secure bond sufficient to allow component 140 to withstand the forces associated with bearing the weight of panels 50, 50' and other forces associated with or applied to the panels.
Fingers 141a, 141b also allow for efficient alignment of component 140 onto wall 130. Fingers 141 are positioned on component 140 to match the gap between hands 132, 132' and to also receive an adhesive between component 140 and wall 130. Wall 130 is bent with corners 133 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 132, 132', 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 140 to wall 130. It may be appreciated that fingers 141 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 140 covers the entirety of outer side 125 of transom 26. Such configuration assures that no portion of transom 26 is in communication with the exterior atmosphere or panels 50, 50' or the pocket 28 between panels 50, 50'. Maintaining such isolation improves the insulating characteristics of system 22.
In a further example polymer component 140 includes a seal receiver 149. Receiver 149 is configured to receive a gasket or seal 60. In one example seal receiver is defined by seal fingers 41. Seal 60 is configured to insert into seal receiver 149 and between component 40, 140, and panel frame 52, i.e., between first arm 144 and panel frame 52. Seal 60 may be bonded to panel frame 52. Seal 60 may be of a conventional variety used in curtain wall systems.
In one example a pressure plate 36 is fastened with a screw 39 to stem 80 of component 140 and applies pressure to seals 60 which in turn apply pressure to panels 50, 50' and against component 140. It may be appreciated that a setting block may be positioned between stem 80 and panel 50. It may be appreciated that component 140 together with pressure plate 36 secure panels 50, 50' to transom 26.
In a further example the stem 80 includes a groove 82 configured to receive a fastener 39 (see also Figure 3B). Groove 82 may include a taper 84 to assist in receiving fastener 39. Groove 82 may be a continuous groove which spans the length of component 40, 140. It may be appreciated that groove 82 operates as a pilot hole to receive and contain fastener 39. In one example groove 82 is configured to securely receive a fastener such as a screw, including a #14 stainless steel HWH SMS screw. A plurality of screws 39 may be inserted along transom to secure a plurality of panels 50, 50' into position. In one instance screws 39 may be positioned at 9 inches on center. Other arrangements may be used as desired.
Figure 3B shows a further example of transom 26 having a symmetrically disposed polymer component 140. Also shown is a setting block 37 positioned between component 140, particularly, between the stem 80 of component 40, and a panel 50. In one example setting block 37 is a silicone block of about 4 inches to 6 inches in length. Block 37 may also be a continuous length to match the length of transom 26 or in other examples may be a shorter length. Block 37 may include a block tip 37a which is a projection from block 37 configured to abut component 40 for appropriate spacing of block 37 beneath panel 50 within pocket 128. In one example a number of setting blocks 37 may be used and staggered at various locations along the system 22. Blocks 37 may be positioned at quarter points along panel 50, for example. Block 37 or blocks 37 allow for the weight of a panel 50 to be transferred to the stem 80 or polymer component 40. Use of blocks 37 may also be employed with reference to Figure 5 and Figure 7. In this manner the weight of panels 50 is supported by polymer component 40. Pressure plate 36, which is secured to polymer component 40 by a fastener 39, for instance, applies pressure to seals 60, 60, which in turn apply pressure to panels 50,50'. In one example seal 60 may include, for instance, a 60-durometer silicone gasket. The interior side seal 60 may include a lineal or molded corner configuration for instance. Pressure plate 36 may also include a weep hole 51 which is an aperture defined by plate 36. Weep hole 51 allows for moisture to escape from pocket 128. A gasket, such as gasket 53 may be positioned between pressure plate 36 and stem 80. Gasket 53 may include a silicone material, such as a 70-durometer silicone gasket separator. It may be appreciated that polymer component 40 extends into pocket 128 between panels 50, 50'. Pressure plate 36 may extend a length of transom 26. Pressure plate 36 may include several weep holes 51 spaced at various positions along the length of plate 36. In one example weep hole 51 may be positioned on pressure plate 36 at a position above polymer component 40 as shown. This allows water or moisture to escape from below panel 50.
Figure 3C shows a further example of transom 26 having a symmetrically disposed polymer component 140. In this example the transom 26 includes a glazing tape 54 between panel 50 and component 40. In one example glazing tape 54 is a two-sided glazing tape. Use of glazing tape 54 secures panel to polymer component 40 which is in turn secured to transom wall 130. In addition, a silicone layer 68 such as structural silicone is also positioned between panel 50 and component 40. Together the glazing tape 54 and structural silicone 68 secure panel to transom 26 while also maintaining a seal relationship. A silicone gasket 69 is positioned at an edge of component 40 and structural silicone 68 for additional insulation and/or for cosmetic purposes to conceal the structure. Gasket 69 inserts into a gasket receiver 69' of component 40. A similar arrangement may also be used to secure panel 50' to transom 26. It may be appreciated that use of glazing tape 54 and structural silicone 68, for instance, allows for securing panel 50 to transom 26 without the use of a fastener such as shown the Figure 3A or Figure 3B. A sealant 64 may be applied between panels 50, 50', for instance, and/or applied to stem 80 of component 40. A setting block 37 may also be used to receive panel 50.
Figure 3D shows a further example of transom 26 having a symmetrically disposed polymer component 40 and where the transom 26 is positioned adjacent a horizontal (such as at a bottom area of a curtain wall system). A single (upper) panel 50 is used in this example. A PVC spacer 67 is positioned between pressure plate 36 and component 40. A sealant 64 and seal 60 may be positioned between the horizontal and cover plate 38 and at the joint of component 40 and transom wall 130. A setting block 37 may be used to set transom 26.
As shown in Figure 4, mullion 224 is made of aluminum. Mullion 224 is made of a first mullion segment 230 and a second mullion segment 232. A polymer component 240 is bonded to mullion 224. In one example polymer component 240 is bonded, by an adhesive and other bonding techniques, to segment 230. Polymer component 240 may include an interlock 242 to receive a mullion finger of segment 230. Interlock 242 in one example is configured as part of first arm 244. First arm 244 may include a lip 243 which inserts into a gap defined by segment 230. Adhesive is applied to the surfaces to bond first arm 244 to segment 230. Bonding treatments and procedures are used to assure a rigid connection. In one example contact surface 245 is bonded to segment 230. Polymer component 240 further includes seal receiver 249. Receiver 249 is configured to receive a seal 60. In one example seal receiver is defined by seal fingers 241. Seal 60 is configured to insert into seal receiver 249 and between first arm 244 and panel frame 52. Seal 60 may be bonded to panel frame 52. Seal 60 may be of a conventional variety used in curtain wall systems.
As shown in Figure 4, transom 224 further includes shoulder 270 laminated or bonded to mullion 224. Particularly shoulder 270 is rigidly connected to segment 232. Shoulder 270 includes interlock 242 which may be the same or similar to interlock 242 defined by polymer component 240. Segment 232 may also include tail 231 which may be friction fit and/or bonded within gap formed by lip 243. Shoulder 270 abuts polymer component 240 and may include seal 264. Shoulder 270 may further include seal receiver 249 to receive seal 60. Shoulder 270 and polymer component 240 are bonded to mullion 224 at outer side 225 and prevent mullion 224 from communication with panels 50, 50' or pocket 228.
With reference to Figure 5, a further example of transom 326 is shown which includes transom wall 330. Polymer component 340 is bonded to transom 326. Polymer component 340 is made of the same or similar material as is the polymer component 40 noted above. Polymer component 340 is configured to friction fit and/or bond with or to outer side 335 of transom 326. In one example polymer component 340 includes a lip 343 which inserts into a gap formed in part by tail 331 of transom wall 330. Transom 326 may be made of aluminum and may be extruded, for instance. Lip 343 and tail 331 create an interlock 342. Polymer component 340 further includes a first arm 344 which includes a seal receiver 349. Receiver 349 is configured to receive a seal 60. In one example seal receiver is defined by seal fingers 341. Seal 60 is configured to insert into seal receiver 349 and between first arm 344 and panel frame 52. Seal 60 may be bonded to panel frame 52. Seal 60 may be of a conventional variety used in curtain wall systems. Polymer component 340 in this example completely covers outer side 325 of transom 326.
With reference to Figure 6, an alternative mullion 24 which is similar to the mullion 24 of figure 2 further includes a fastener 72 such as a screw. Fastener 72 includes additional support to further inhibit separation of polymer component 40 from mullion 24. In one example fastener 72 is positioned through first arm 44 of polymer component 40 and through tail 31 of steel segment 30. A sealant may also be inserted to cover the head of fastener 72 and to seal the opening (or edges of the opening) which is created by fastener 72. Use of fastener 72 provides enhanced protection in the event of a fire situation where temperatures can be extreme. It is envisioned that the bonding of polymer component 40 (and shoulder 70) will withstand very high temperatures without separation and/or with use of fastener 72 such separation will be inhibited or prevented. Polymer component 40 is made of fire-retardant material. Accordingly, the features presented in Figure 6 provide a mullion with an enhanced fire rating.
Figure 7 shows transom 26 where fastener 72 is inserted through polymer component 140 where polymer component 140 is also bonded to transom 26. This arrangement has similar separation inhibiting example as noted with Figure 6.
Figure 8 shows a polymer component 40 bonded to mullion 24. In this example mullion 24 includes first mullion segment 30 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 40 is bonded to segment 30 at tail 31a, arm 31b and hand 31c. Mullion 24 also includes second mullion segment 32 which includes shoulder polymer component 70. Component 70 is made of the same or similar material as component 40. Component 70 is bonded to segment 32 at tail 35. It may be appreciated that the exterior surface of tail 35 is covered from the atmosphere or from communication with panel 50' or pocket 128. It may also be appreciated that the exterior surface of segment 30, such as at tail 31a, arm 31b and hand 31c, is also covered from the atmosphere or from communication with panel 50 or pocket 128. Component 70 may wrap at least in part at a tip of tail 35. Component 40 and component 70 include seal receiver 49, 49' to receive respective seals 60.
Figure 9 shows a polymer component 40 and a polymer component 70 bonded to mullion 24. The bonding is achieved by use of an adhesive applied. In this example component 40 is devoid of a stem and does not include an element which projects into pocket 128. Panels 50, 50' are secured to component 40 and component 70, respectively, with glazing tape 54 and structural silicone 68. A sealant 64 and seal 60 are applied between panels 50, 50'.
Figure 10 shows a polymer component 40 bonded to mullion 24. In one example mullion 24 is formed of bent sheet steel. In this view mullion 24 is positioned adjacent or against a vertical wall and connects with a transom 26 having wall 130. Transom 26 also includes an end plate 135 welded at an end of transom 26. End plate 135 receives fasteners which pass through mullion 24. A single segment mullion 24 is configured with opposing walls 132, 132' to accommodate adherence of fingers 141a, 141b. Segment 40 is bonded to mullion 24 as noted above with respect to the further examples. Segment 40 includes seal receivers 49, 49' to receive a seal 60 and/or a PVC spacer 67. It may be appreciated that an entirety of an outside surface of mullion 24 is isolated from the atmosphere or from communication with panel 50' and/or pocket 128. It may be appreciated that panel 50' may also be fastened to mullion 24 by use of glazing tape and silicone gasket as desired (and as an alternative to use of a fastener and/or stem 80).
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 24 (or transom 26) 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 24 may be of varying lengths depending on the desired application. In one example, mullion 24, and thus segment 30 may have a length of up to 24 feet, or at least 24 feet. A press that is 24 feet long, or at least 24 feet long may be used to form mullion 24 at such length. Mullion 24 may also be of smaller length as desired and smaller presses and tooling may also be used. Mullion 24 may be formed at a variety of widths. In one example mullion 24 may vary in width from 1 ¾ inches (45 mm), for instance, to 4 inches (100mm) or more, and may vary in depth from 4 inches (100 mm), for instance, up to 16 inches (405mm) 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 24 feet, or even greater than 20 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 80 extending in a first direction from a base 81, first arm 144 and second arm 146 extending from opposite sided of base 81 and each extending perpendicular to the stem 80 and each defining a seal receiver 149 having an opening toward the first direction. In a further example the stem 80 includes a groove 82 configured to receive a fastener 39. Groove 82 may include a taper 84 to assist in receiving fastener 39. Groove 82 may be a continuous groove which spans the length of component 40, 140. It may be appreciated that groove 82 operates as a pilot hole to receive and contain fastener 39. In one example groove 82 is configured to securely receive a fastener such as a screw, including a #14 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 81 opposite stem 80. Fingers 141 are configured to align with a curve of metal structure 26, and particularly configured to conform to opposing hands 132, 132'. While other arrangements are available, in one example fingers 141 are symmetrically separated by a distance greater than the width "w" of stem 80. The thermally insulating component 40 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 40, 140 (and components 70, 170, 270) 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 125 of metal structure 26. In one example the fiberglass material is a polymer component 40 having fingers 140 that fit with respective hands 132 of the metal structure 26. In further examples the method includes bonding the component 40 to the cover the entirety of the outer side 125 of metal structure 26.
Figure 11 is a section view showing the claimed invention. Transom 426 is a metal structure and includes a metal first segment 430 and a metal second segment 432 connected thereto. Segments 430, 432 may be made of extruded metal such as aluminum. Segment 432 may snap-fit into connected position. Transom 426 has an outer side 433 which is oriented toward or facing panels 50 or an outside of the building to which transom 426 is connected. Segment 430 includes an access port 434 such that when segment 432 is not connected to segment 430, access is made available to inside 435 of transom 426. Particularly, access may be made through port 434 such that a fastener 39 can be inserted into and through segment 430. Fastener 39 is inserted such that a head 39a of fastener 39 abuts inner surface 436 of transom 426. Fastener 39 is inserted through segment 430 to outer side 433 of transom 426.
Transom 426 includes a component 440 connected to transom 426 at outer side 433. Component 440 may be made of materials noted above regarding components 40, 140. In one embodiment component 440 includes a head 442 which inserts into a pocket 438 of segment 430. Head 442 may include ear or ears 444 which in one embodiment insert into interlocking slots 445 defined at least in part by pocket rib 446. Component 440 also includes shoulder 448 or opposing shoulders 448 which abut transom 426 at outer side 433. Particularly, shoulder 448 abuts and covers outer side face 433' of segment 430. It may be appreciated that component 440 abuts and covers the entirety or substantially the entirety of outer side 433 of segment 430. Covering the entirety of outer side 433 isolates the metal transom 426 from the outside and insulates transom 426. Component 440 also defines a bore such as head bore 450 which is configured to receive fastener 39. Head bore 450 opens toward head 442 such that fastener 39 penetrates through segment 430 and into bore 450. Bore 450 is a closed bore in that bore 450 is closed opposite head 442 (i.e., the bore does not run through the component). In this manner component 440 may be fastened to transom 426 without exposing any part of transom or outer side 433 to the elements. There are no perforations made through component 440 which would otherwise tend to cause moisture or cold or outside air to contact transom 426. Bore 450 also allows for efficient insertion or securing of fastener 39 to component 440. Given the nature of the materials used to make component 440 (reinforced fiberglass), bore 450 allows the fastener 39 to penetrate or connect to component 440 without undue trauma to component 440. The absence of bore 450 might otherwise cause component 440 to splinter or crack or otherwise become weak when fastener 39 is inserted. In one instance fastener 39 includes self-threading threads which impart corresponding thread grooves in component 440 at bore 450. Opposite from bore 450 is stem bore 452 defined by stem 480. Bore 452 receives a fastener 39. Fastener 39 may secure pressure plate to transom 426. Bore 452 opens outward and has a closed end or bottom oriented toward segment 430. Shoulder 448 may include a seal receiver 49 to receive a seal 60. Seal 60 abuts panel 50. A spacer or setting block 37 is positioned on component 440 at stem 480. Upon block 37 rests panel 50. It may be appreciated that panel 50 will have a weight and the weight is supported by component 440. Component 440 extends between or into a gap between panels 50, 50. In this manner component 440 is a structural support of panel 50. It may be appreciated that component 440 extends the entire length or substantially the entire length of the face or outer side 433 of segment 430.
In some embodiments component 440 is positioned within pocket 438 of segment 430 by longitudinally inserting head 442 into pocket 438 and sliding component 440 longitudinally within pocket 438. Component 440 and segment 430 may be placed end-to-end for sliding action. Once head 442 and component 440 are slid into position within pocket 438, a fastener 39 or series of fasteners may be secured to transom 426. Particularly, a fastener 39 is positioned to inside 435 and placed against inner surface 436. A drill or screwdriver is activated to drive fastener 39 through segment layer 430 and into bore 450 of head 442 of component 440. A series of fasteners 39 may be inserted along the longitudinal aspect of component 440. Fasteners 39 may be inserted via angled drill/drive devices. Fasteners 39 may be inserted robotically. After insertion of fasteners 39, second metal segment 432 is connected to first metal segment 430 to form transom structure 426. In a further embodiment, component 440 may also be bonded to metal segment 430. In one instance shoulder 448 may be bonded to outer side face 433' 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 448 to segment 430. Adhesive may also be used to secure head 442 within pocket 438. Various designs and configurations of head 438 may be used.
Component 440 is a thermally insulating fiberglass reinforced polymer component 440. Component 440 is for use with a curtain wall mullion 426 or transom of a curtain wall system. In some embodiments component 440 includes a head 442 configured to insert into a pocket 438 defined at an outer side 433 of a metal mullion or transom 426 of the system. Opposing shoulders 448 define seal receivers 49 configured to receive a seal oriented to abut a panel 50 of the system. Each of the shoulders 448 are configured to about the outer side 433 of the metal structure 426 such that component 440 covers substantially an entirety of the outer side 433. As shown in Figure 11, component 440 covers the entirety of the outer side 433 at outer side face 433'. A stem 480 is configured to project into a space between a first panel 50 and a second panel 50 of the system. Stem 480 provides structural support of the panel 50. Component 440 comprises a unitary thermally insulating fiberglass reinforced polymer. In some embodiments component 440 comprises pultruded fiberglass reinforced polymer. The head 442 defines a head bore 450 configured to receive a fastener 39 inserted through the metal structure 426 and into the component 480. In embodiments, stem 480 defines a stem bore 452 configured to receive a fastener 39. The fastener 39 received in stem bore 452 may be of a different, or the same, variety as the fastener received at head bore 450. Stem bore 452 in one embodiment is oriented opposite head bore 450.
Figure 12 is a section view of a further embodiment of the claimed invention. Transom 426' is a steel transom having a steel first segment 430' and a metal second segment 432' which may also be made of steel. Segment 432' may slide into connected position and friction fit into secure placement. Access port 434' is used to insert fastener 39 through segment 430' and into component 440. Shoulder 448' is connected to outer side face 433. An adhesive and heat and pressure techniques may be used to secure or bond shoulder 448' to outer side face 433'. An adhesive layer may be inserted between shoulder 448' and face 433'. Fastener 39 is inserted from within segment 430'. Several fasteners 39 may be inserted though segment 430' to secure component 440 along the longitudinal length of segment 430'. It may be appreciated that with the design of pocket 438' (which lacks ribs 446), head 442 of component 440 may be inserted by translating component 440 into the pocket 438' and without requiring a longitudinal sliding action.
Figure 13 is a section view of a further embodiment of the claimed invention. Mullion 526 is an aluminum mullion having first segment 530 and a second segment 532 connected thereto. Fastener 39 is positioned at inside 535 of mullion 526 and driven through wall of segment 530 into component 540. Component 540 includes a head which inserts into pocket 538. Pocket ribs 546 may be used as interlock elements to assist in locking component 540 or aligning component 540 within pocket 538. An additional component 541 is connected to segment 532 such that together component 540 and component 541 cover an entirety or substantially the entirety of outer side 533 of mullion. Component 541 may be made of the same or similar material used to make component 540, namely a fiberglass reinforced polymer, and in some embodiments may be an insulating pultruded fiberglass reinforce polymer.
Figure 14 is a section view of a further embodiment of the claimed invention. Mullion 526' is a steel mullion having a first segment 530' and a second segment 532' connected thereto. Second segment 532' may also be made of steel. Component 540' is secured to segment 530' with a fastener 39. An optional washer may be placed between fastener 39 and the inner surface 536 of segment 530'. An optional washer may also be used with the other embodiments described herein. A second component 541' is connected to segment 532'. Component 541' may be bonded to segment 532'. Second component 541' may also be connected to segment 532' with a fastener which runs from inside 535' of mullion 526 through a wall of transom segment, either 530' or 532', and into component 541'.
Figure 15 is a section view of a further embodiment of the claimed invention. Mullion 626 includes a metal segment 630 and a second metal segment 632 which slide together for an adjustable connection. For instance, segments 630, 632 may slide relative to each other in the direction of arrow A to form a mullion 626. A fastener 39 inserts from inside 635 of segment 630 through a wall of segment 630 and into component 640. Component 640 is made of a polymer material as noted herein. Component 640 is connected to segment 630 by fastener 39. Interlock rib 646 may be used to form an interlock to secure component 640 within a pocket 638. Component 640 is slid longitudinally into pocket 638 to be secured to segment 630 and/or secured via fastener 39 and/or both. An adhesive may also be used to secure component 640 to segment 630. An adhesive bonding may be used together with a fastener and also together with an interlock as desired. As shown in Figure 15, a rib or ribs and pocket similar to rib 646 and pocket 638 may also be provided by segment 632 to secure component 641. An interlock and/or fastener 39 and/or both and/or adhesive and/or all of such connections may be used to connect component 641 to segment 632. An adhesive may also be used, including an adhesive layer together with heat and pressure treatments used to bond or secure component 640, 641 to mullion 626.
Component 640, 641 includes stem 680 which extends between panels 50. A leg 690 wraps laterally and over (and covers) a portion of panel 50 as shown. A portion of panel 50 is also covered by shoulder 648. Shoulder 648 and leg 690 each define a seal receiver 49. Component 640 may be secured to segment 630 using several fasteners 39. Thereafter panel 50 may be secured using component 640 and with seal placed in seal receivers 49 and adhered to panel 50. Likewise, component 641 may be fastened to segment 632 with several fasteners 39 and then panel 50 connected to component 641 by use of seals and adhesive. Segment 630 and segment 632 may then be slid or adjustably connected together. The segments 630, 632 may also be conveniently disconnected by relative sliding along direction of arrow A. When segments 630, 632 have been connected together, mullion 626 may be connected to the building structure. It may be appreciated that an entirety or substantially the entirety of outer side 633 of combined segment 630, 632 (or of individual segments 630, 632) is covered by components 640, 641 with portions of components 640, 641 contacting segments 630, 632. Further, it may be appreciated that no pressure plate or exterior fastener is required to secure panel 50 to segments 630, 632. In one embodiment, components 640, 641 comprise pultruded fiberglass polymer and are configured to wrap about the edge of panel 50. Components 630, 632 define bore 450 to receive fasteners 39.
Figure 16 is a section view of a further aspect of the invention. transom 726 which includes metal segment 730 and metal segment 732 connected thereto. A wing 727 projects from segment 730 to a gap between panels 50, 50. Fastener 39 is secured through wing and into component 740. Component 740 may include a bore to receive fastener 39. In one example wing 727 projects perpendicularly or generally perpendicularly from outer side face 733'. In one example, fastener 39 is oriented perpendicular or generally perpendicular to wing 727. Component 740 may be a polymer component as described herein. A second component 741 is connected to segment 732. Component 741 may be connected via adhesive or bonding. A fastener may also be secured from and through inside of segment 732 and into component 741. In further examples component 741 may include a bore to receive a fastener. Component 740 wraps around to both sides of panel 50 as shown. An entirety of outer side 733 of combined segment 730, 732 is covered by components 740, 741, 742. Such components 740, 741, 742 also contact outer side 733 of segments 730, 732. Component 741 may include an interlock which inserts into a corresponding interlock of segment 732. Component 741 may also include a seal receiver which receives a seal to abut against panel 50. An additional component 742 may be used to cover wing 727 as shown and to provide further insulating protection of segments 730, 732. Component 742 may be connected to wing 727 by adhesive and/or a fastener. A further component 743 includes a seal receiver and receives a seal to abut against panel 50. Component 743 may comprise a metal or in other examples may also comprise a fiberglass component. An end of component 743 opposite seal receiver includes a rib or ribs which insert into corresponding rib or ribs of component 740 for secure positioning of component 743. In addition to use of fastener 39, or as an alternative to fastener 39, an adhesive may be used to rigidly bond component 740 to outer side face 733'. Such bonding may be made by use of an adhesive and other forms of bonding may also be used. Additionally, or alternatively, a rib 746 may also be used to secure or assist in rigidly securing component 740 to face 733'. A spacer may be inserted into cavity 792 of transom 726 so that panel 50 may rest against the spacer so that the weight of panel 50 may be supported by component 740. Component 740 may also include a weep hole or weep holes to allow moisture to escape from cavity 792.
Figure 17 is a section view of a further aspect of the invention. transom 826 which includes metal segment 830 which may be aluminum for instance. Segment 830 mates with segment 832 which may also be made of metal such as aluminum. Component 840 is connected to outer side 833 of transom 826. In one example component 840 connects to wing 827 and is configured to cover the entire outer side of segment 830. Component 840 may include a bore configured to receive fastener 39 inserted through wing 827. An adhesive may also be used to secure component 40 to segment 830. 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 840 to segment 830. Segment 830 may include a rib 846 or ribs which mate with component 840 for interlocking arrangement. Component 840 may include leg 890 which extends to an outer side of panel 50 and transom 826 and may include a seal receiver to receive a seal to abut against panel 50. Component 840 may also include a weep hole 891 or a series of weep holes to allow moisture to escape from cavity 892. Component 840 includes a further seal receiver to receive a seal to abut panel 50 on an inner side of panel 50. It may be appreciated that component 840 wraps around to both sides of panel 50. A spacer may also be positioned in cavity 892 so that panel 50 may rest upon the spacer which in turn rests upon component 840. Component 840 supports the weight of panel 50.
A component 841 is connected to segment 832 at jaw 829. The entirety of the outer side of jaw 829 is covered by component 841. Component 841 wraps around a tip of jaw 829. Component 841 includes a seal receiver for receiving a seal to abut against an inside of segment 830. An optional air baffle 843 is placed within segment 839. In one example baffle 843 may be about 4 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 843 fits snugly into a channel defined in part by various walls of segment 830 as shown. A tip of jaw 829 inserts into the channel and the component 841 abuts baffle 843 which also seals outer face of segment 830 from exposure. Segment 842 is also connected to segment 830 and covers wing 827 and isolates wing 827 and walls of segment 830 from the atmosphere or exposure. It may be appreciated that components 841, 842 may be secured to segments 830, 832 by adhesive, including a double backed strip adhesive and under pressure and temperature for bonding. In alternative examples components 841, 842 may also be fastened with a fastener. Components 841, 842 may also define respective bores for receiving fasteners. Components 840, 841, 842 may be secured by use of adhesive and/or fasteners and/or interlock/friction fit or all of the same. An end cap 893 connects securely to component 840 via friction fit or snap-on fingers and includes a seal receiver and seal to abut panel 50 which is held in place at panel 832. An adhesive block or connector 895 is used to secure panel 50 to segment 832. It may be appreciated that segments 830 and 832 come together to form transom 826 and the individual segments 830, 832 are connected to respective structure elements of the building to secure transom 826 and panels 50 into position. While the unitized design shown in Figure 17 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.
It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made. The scope of this invention is defined by the appended claims and also includes embodiments having different combinations of features and embodiments that do not include all of the above-described features.

Claims

A curtain wall mullion or transom for use on a curtain wall system, the mullion or transom comprising:
a metal mullion or transom structure (430, 430', 530, 530', 630) having an outer side (433, 533, 633); and

a fiberglass reinforced thermally insulating polymer component (440, 540/541, 540'/541', 640/641) having a width which spans a total width of the outer side of the metal mullion or transom structure (430, 430', 530, 530', 630),

wherein the component (440, 540/541, 540'/541', 640/641) abuts the outer side of the structure (430, 430', 530, 530', 630) and covers the entirety of the outer side of the structure (430, 430', 530, 530', 530), the component (440, 540/541, 540'/541', 640/641) being connected to the metal structure (430, 430', 530, 530', 630) at the outer side by a first fastener (39) having a head, characterized by

the first fastener (39) passing through the metal structure (430, 430', 530, 530', 630) and into the component (440, 540/541, 540'/541', 640/641), the head (39a) positioned at an inside of the structure (430, 430', 530, 530', 630).
The mullion of transom of claim 1, further comprising a second fastener (39) passing through a pressure plate (36) and then into the component (440, 540/541, 540'/541', 640/641).
The mullion or transom of claim 1 where the component (440, 540/541, 540'/541', 640/641) is a structural support of a panel (50) to be used with the system, the component (440, 540/541, 540'/541', 640/641) including a stem (480, 680) configured to project into a space between a first panel (50) and a second panel (50) of the system.
The mullion or transom of claim 1 where the component (440, 540/541, 540'/541', 640/641) is devoid of penetrations passing through the component (440, 540/541, 540'/541', 640/641).
The mullion or transom of claim 1 where the component (440, 540/541, 540'/541', 640/641) defines a first seal receiver (49) configured to receive a seal oriented to abut a first panel (50) of the system and defines a second seal receiver (49) configured to receive a seal.
The mullion or transom of claim 1 where the metal structure (430, 430', 530, 530', 630) includes an access port (434, 434', 534, 534', 634) configured to allow access to an inside of the metal structure (430, 430', 530, 530', 630) to secure the fastener (39) through the metal structure (430, 430', 530, 530', 630) to the component (440, 540/541, 540'/541', 640/641).
The mullion or transom of claim 3 where the fastener head (39a) abuts an inner surface (436) of the metal structure (430, 430'), the component (440) comprising opposing shoulders (448, 448'), each shoulder abutting the outer side (433) such that the component (440) covers the entirety of the outer side.
The mullion or transom of claim 1 wherein the component (540/541, 540'/541', 640/641) comprises a first fiberglass reinforced polymer component (540/540', 640) and a second fiberglass reinforced polymer component (541, 541', 641), the first and second components (540/541, 540'/541', 640/641) connected to the outer side (533, 633), the second component (541, 541', 641) and the first component (540, 540', 640) positioned side-by-side and together covering the entirety of the width of the outer side (533, 633).
The mullion or transom of claim 1 wherein the outer side of the metal mullion or transom structure (430, 430', 530, 530', 630) defines a pocket (438, 438', 538, 638), and the component (440, 540, 540', 640, 641) has a head (442) inserted into the pocket (438, 538, 638) and opposing shoulders (448, 448', 648) where each shoulder (448, 448', 648) defines a seal receiver (49) configured to receive a seal oriented to abut a panel of the system (50), each shoulder (448, 448', 648) abuts the outer side (433, 633) such that the component (440, 540/541, 540'/541', 640/641) covers an entirety of the outer side (433, 633), the component (440, 540, 540', 640, 641) further comprising a stem (480, 680) configured to project into a space between a first panel (50) and a second panel (50) of the curtain wall system.
The mullion or transom of claim 9 the component (440, 540/541, 540'/541', 640/641) having a total length, the head (442) defining a pre-set slot spanning at least the total length, the fastener (39) passing into the pre-set slot.
The mullion or transom of claim 9 where the head (442) has an ear (444) interlocking with a rib (446, 546, 646) within the pocket (438, 538, 638), the metal mullion or transom structure (430, 430', 530, 530', 630) being one element of a cell having a first mullion, a second mullion, a first transom and a second transom, the system further comprising a panel securable to the cell.
A method of manufacturing a mullion or transom for use on a curtain wall system, the method comprising the steps of:
positioning a component (440, 540/541, 540'/541', 640/641, 740/741/742, 840/841/842) at an outer side of a metal mullion or transom structure (430, 430', 530, 530', 630, 730, 830), the component (440, 540/541, 540'/541', 640/641, 740/741/742, 840/841/842) comprising a fiberglass reinforced thermally insulating polymer component having a width which spans a total width of the outer side of the metal mullion or transom structure (430, 430', 530, 530', 630, 730, 830), the component (440, 540/541, 540'/541', 640/641, 740/741/742, 840/841/842) abutting the outer side (433, 533, 633, 733, 833) of the structure (430, 430', 530, 530', 630, 730, 830) and covering an entirety of the outer side (433, 533, 633, 733, 833) of the structure (430, 430', 530, 530', 630, 730, 830); and

inserting a fastener (39) through the metal structure (430, 430', 530, 530', 630, 730, 830) and then into the component (440, 540, 540', 640/641, 740, 840).
The method of claim 12 where the component (440, 540, 540', 640/641, 740/742, 840/842) is a structural support of a panel (50) to be used with the system, the component (440, 540, 540', 640/641, 740/742, 840/842) comprises a stem (480, 680) configured to project into a space between a first panel (50) and a second panel (50) of a curtain wall, the component (440, 540/541, 540'/541', 640/641, 740/741, 840/841) defining a first seal receiver (49) configured to receive a first seal oriented to abut the first panel (50) and defines a second seal receiver (49) configured to receive a second seal.
The method of claim 12 further comprising inserting a second fastener (39) into the component (440, 540, 540', 640/641), the component (440, 540/541, 540'/541', 640/641, 740/741/742, 840/841/842) devoid of penetrations passing through the component (440, 540/541, 540'/541', 640/641, 740/741/742, 840/841/842) from an outer side (433, 533, 633, 733, 833) of the component (440, 540/541, 540'/541', 640/641, 740/741/742, 840/841/842) to an inner side of the component (440, 540/541, 540'/541', 640/641, 740/741/742, 840/841/842).