System and method for retrofitting architectural glass systems

文档序号：1559606 发布日期：2020-01-21 浏览：32次中文

阅读说明：本技术 用于改造建筑玻璃系统的系统和方法 (System and method for retrofitting architectural glass systems ) 是由 A·阿卡萨斯于 2018-04-12 设计创作，主要内容包括：公开了用于改造建筑玻璃系统的玻璃罩系统和方法。玻璃罩系统包括支撑框架和组合板。在某些实施例中,玻璃罩系统可以以非侵入性和非破坏性的方法安装在现有的玻璃系统上。在一个实施例中,可以使用结构性粘合剂将支撑框架附接到现有的玻璃系统的填充板,并且可以将组合板安装在支撑框架上,从而形成隔热的玻璃罩。(Glass cover systems and methods for retrofitting architectural glass systems are disclosed. The glass cover system includes a support frame and a composition plate. In certain embodiments, the glass cover system can be installed on existing glass systems in a non-invasive and non-destructive manner. In one embodiment, a structural adhesive may be used to attach the support frame to the infill panel of an existing glass system, and the composite panel may be mounted on the support frame, thereby forming an insulated glass cover.)

1. A system for retrofitting an existing glass system, comprising:

a support frame comprising:

an upper stop member having first means for interconnecting,

a lower rail member having a second means for interconnecting,

a first side rail member connecting the upper rail member to the lower rail member,

a second side rail member connecting the upper rail member to the lower rail member,

a peripheral attachment device for attaching the support frame to an existing infill panel of existing glass,

a composition plate removably coupled to a support frame, the composition plate comprising:

a unit frame comprising:

a head profile member shaped to cooperate with first means for interconnection,

a sill profile member shaped to cooperate with a second means for interconnection,

a first mullion member connecting a head section member to a sill section member,

a second mullion member connecting the head section member to the sill section member,

a filler board coupled to the unit frame, and

attachment means for coupling the infill panel to the cell frame.

2. The system of claim 1, wherein the first means for interconnecting comprises a first hooked profile and the second means for interconnecting comprises a second hooked profile.

3. The system of claim 2, wherein the cross-sectional shape of the head profile member comprises a first inverted hook shape to mate with a first hook profile and the cross-sectional shape of the sill profile member comprises a second inverted hook shape to mate with a second hook profile.

4. The system of claim 3, wherein the first rail member defines at least one first side rail opening and the second side rail member defines at least one second side rail opening.

5. The system of claim 4, wherein the first mullion member includes at least one first vertical protrusion sized to fit within at least one first side rail opening, and the second mullion member includes at least one second vertical protrusion sized to fit within at least one second side rail opening.

6. The system of claim 5, wherein the at least one first vertical protrusion has a hook shape sized in height to mate with a portion of a support frame positioned around the at least one first side opening, and the at least one second vertical protrusion has a hook shape sized in height to mate with a portion of a support frame positioned around the at least one second side opening.

7. The system of claim 1, wherein the peripheral attachment means and the attachment means for coupling the infill panel are structural adhesives.

8. The system of claim 1, further comprising an insulating glass system comprising:

a first low water vapor transmission rate seal between the support frame and the existing infill panel,

a second low water vapor transmission rate seal between the unit frame and the support frame at the periphery of the unit frame, and

a third low water vapor transmission rate seal between the cell frame and the infill panel at the periphery of the infill panel.

9. The system of claim 8, wherein the insulating glass system further comprises a first drying element positioned between the fill panel and the unit frame and a second removable drying element positioned between the unit frame and the support frame.

10. The system of claim 1, wherein the infill panel is a laminated glass panel comprising at least two layers forming a peripheral step between layers such that an outer layer extends to the periphery of the cell frame.

11. The system of claim 1, wherein the existing infill panel is a new infill panel.

12. The system of claim 1, further comprising at least one peripheral external seal coupled to an external peripheral surface of the compoboard.

13. The system of claim 1, further comprising an intelligent system, the intelligent system comprising:

a controller, comprising:

a processor for processing the received data, wherein the processor is used for processing the received data,

a memory in communication with the processor and configured to,

a power management circuit in communication with the processor,

a radio broadcasting device in communication with the controller for receiving the operation instructions and transmitting the status information, an

An energy storage device in communication with the processor,

a substantially transparent photovoltaic cell coupled to the fill sheet and electrically coupled to the power management circuit and the energy storage device.

14. The system of claim 13, further comprising an electrochromic conductive layer coupled to the filler board and in electrical communication with the processor.

15. The system of claim 13, wherein the controller and the energy storage device are located within one or more cavities formed by the support frame and the cell frame.

16. A method of installing a retrofit system onto an existing filler plate of a glass system, the method comprising:

the support frame is coupled to an existing infill panel,

detachably coupling a composition plate having a unit frame to a support frame by:

the head section members of the unit frame are engaged with the upper rail members of the support frame,

the sill member of the unit frame is mated with the lower rail member of the support frame such that the composition board is coupled to the existing infill panel through the support frame.

17. The method of claim 16, wherein coupling the support frame to an existing infill panel comprises: a structural adhesive is coupled to the support frame and pressed against the existing infill panel.

18. The method of claim 16, further comprising:

the top rail member is coupled to a first peripheral region of the existing infill panel,

the bottom rail member is coupled to a second peripheral region of the existing infill panel,

coupling a first side rail member to the upper rail member and the lower rail member, an

A second side rail member is coupled to the upper rail member and the lower rail member.

19. The method of claim 16, further comprising:

inserting at least one first protrusion of a first mullion member of a unit frame through at least one first side rail opening,

hooking the at least one first protrusion to a portion of the first mullion member adjacent to the at least one first side rail opening,

at least one first protrusion is moved into the horizontal leg of the opening to secure the first hooked protrusion in a vertical direction.

20. An insulating glass-filled panel system comprising:

a first filling plate is arranged on the first side of the plate,

a support frame coupled to the first infill panel, the support frame comprising:

an upper stop member having first means for interconnecting,

a lower rail member having a second means for interconnecting,

a first side rail member connecting the upper rail member to the lower rail member,

a second side rail member connecting the upper rail member to the lower rail member,

peripheral attachment means for attaching the support frame to the first infill panel,

a composition plate removably coupled to a support frame, the composition plate comprising:

a unit frame comprising:

a head profile member shaped to cooperate with first means for interconnection,

a sill profile member shaped to cooperate with a second means for interconnection,

a first mullion member connecting a head section member to a sill section member,

a second mullion member connecting the head section member to the sill section member, an

A second infill panel coupled to the cell frame.

Technical Field

The present invention relates generally to glass systems such as windows and curtain walls, and more particularly to systems and methods for retrofitting architectural glass systems.

Background

The building is the first end user of the energy source. They account for approximately 40% of all energy consumption and carbon emissions in developed and developing countries. One of the main reasons behind such enormous costs is that most existing buildings today have a history of more than 20 years and therefore, most existing building systems perform poorly and inefficiently compared to the prior art. This is why many cities that have recently been devoted to reducing greenhouse gas emissions have begun to target the energy efficiency of existing buildings, taking measures to address all building systems, particularly those associated with and affected by building envelopes.

An important aspect of a building envelope is that its thermal performance and weatherability determine the amount of energy required to maintain a comfortable indoor environment relative to the outdoor. Indeed, in addition to lighting, building envelope components can significantly affect heating, cooling and ventilation loads, all of which are major areas of energy consumption in building operations. For example, it is estimated that about one third of the energy consumption for heating and cooling in commercial buildings is associated with windows.

In this regard, some research reports emphasize that 20-40% of the total amount of building energy savings is expected to come from windows and building envelopes. This is because windows, curtain walls and skylights, until the 1980 s, were predominantly single-pane glass with a frame without insulation. These inefficient glass systems result in a large loss of heat in winter and an increase in heat in summer, thus resulting in a need for more energy consumption for heating and cooling to maintain a comfortable indoor environment.

Today, it is estimated that, for example, about 40% of all commercial and multi-family residential buildings in the united states still have single-layer windows, and about half of the remaining 60% have early or poorly performing double-layer window systems that are significantly less performing than current technology and building and energy legislation requirements. The problem is that replacing these inefficient glass systems with new, high performance glass systems is generally not a viable option for most buildings due to the associated complexity, high upfront costs, building and service outages, and long payback periods.

In addition, most glazing systems, including current glazing systems, are designed with little, if any, consideration given to the high likelihood that these systems will need to be retrofitted in the future, thus limiting the options for the building owner when a need arises. This is why most of the appearance and window modification practices available today include invasive and complex measures associated with high upfront costs, construction and service outages, and long payback periods, and therefore, for most buildings, they are not generally considered a viable option.

Thus, there is an increasing technical and environmental need for a viable glass and window modification solution that can be widely adopted by most existing buildings to improve their energy efficiency.

Disclosure of Invention

Glass cover systems and methods for retrofitting architectural glass systems are disclosed. The glass cover system includes a support frame and a composition plate. In certain embodiments, the glass cover system can be installed on existing glass systems in a non-invasive and non-destructive manner. In one embodiment, a support frame may be attached to a filler panel of an existing glass system using a structural adhesive, and a composite panel may be mounted on the support frame, thereby capturing a quantity of air between the filler panel of the existing glass system and the composite panel of the present disclosure, forming an insulated glass enclosure.

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

Drawings

FIG. 1 shows a portion of a prior art glass system.

Fig. 1A-a are vertical cross-sectional views through a beam or a portion of the prior art glass system of fig. 1.

1B-B are horizontal cross-sectional views through a mullion or a portion of the prior art glass system of FIG. 1.

FIG. 2A is a partial isometric view of one embodiment of a system for modifying an existing glass system.

Fig. 2B is an exploded isometric view of the embodiment shown in fig. 2A.

Fig. 3A is an isometric view of a support frame of the system shown in fig. 2A.

Fig. 3B is a vertical cross-sectional view of the cross beam of fig. 1A-a coupled to the lower portion of the first support frame and the upper portion of the second support frame.

FIG. 3C is a horizontal cross-sectional view of the mullion of FIGS. 1B-B coupled to a side rail of a first support frame and a side rail of a second support frame.

Fig. 4A is an isometric view of a composite plate of the system shown in fig. 2A.

Fig. 4B is a vertical sectional view of the cross member and the support frame coupled to the lower portion of the first combination board and the upper portion of the second combination board of fig. 3A.

Fig. 4C is a cross-sectional view of the mullion and support frame coupled to a side of the first composite panel and a side of the second composite panel of fig. 3B.

Fig. 4D is a vertical sectional view of an alternative embodiment, showing the lower portion of the first support frame and the upper portion of the second support frame coupled to the lower portion of the first combination plate and the upper portion of the second combination plate, respectively.

Fig. 4E is a partial cross-sectional view of one embodiment showing the lower portion of the cell frame or profile.

FIG. 5 is an exploded isometric view of the support frame of FIG. 3A illustrating one method of assembly.

Fig. 6A is a detailed cross-sectional view showing an alternative embodiment employing an intelligent system.

Figure 6B is a functional diagram of one embodiment of an intelligent system that may be incorporated in certain embodiments of the present disclosure.

FIG. 6C is a detailed functional diagram of one embodiment of certain components of the intelligent system of FIG. 6B.

Detailed Description

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments, or examples, illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

When discussing descriptions such as up, down, top, bottom, clockwise, counterclockwise in this disclosure, the descriptions are intended to provide reference directions only for the illustrated drawings and the orientation of the components in the drawings. These descriptions should not be construed as implying any actual usage in any resulting invention or actual use. In no event should such description be construed to limit or impart any meaning to the claims.

Well-known elements have not been described in detail so as not to obscure the invention in unnecessary detail. In most instances, details which are not necessary to obtain a complete understanding of the present invention have been omitted inasmuch as such details are within the skills of persons of ordinary skill in the relevant art. Details regarding the control circuitry or control devices are within the ability of one of ordinary skill in the relevant art. Accordingly, such devices, circuits, and controllers have been simplified to illustrate elements that are relevant for a clear understanding, while eliminating, for purposes of clarity, many other elements found in such electronic devices. Those of ordinary skill in the art may recognize that other elements and/or steps are desirable and/or required in implementing certain controllers and circuits. However, because such elements and steps are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements and steps is not provided herein.

Existing glass system

FIG. 1 is an isometric view illustrating a portion of an exemplary prior art glass system 40. In the illustrated embodiment, the existing glass system 40 may be a mechanically glazed, modular curtain wall system that generally includes an anchor assembly 42, a vertical rail assembly 44, a horizontal rail assembly 46, and a filler panel 48. The anchor assembly 42 is typically attached to a building structure 41, such as a concrete floor, and serves to transfer the load of the component curtain wall to the building structure. For illustrative purposes, the existing filler plate 48 may be a one-piece glass plate.

Fig. 1A-a show a vertical cross-sectional view of a typical prior art horizontal rail assembly 46, the horizontal rail assembly 46 connecting an upper portion of an existing infill panel 48a and a lower portion of an existing infill panel 48 b. Since the details of existing rail assemblies vary widely, they will not be discussed in depth here. Typically, however, for the horizontal rail assembly 46, there is a cross beam 47 and a cross beam cover 49, the cross beam cover 49 being coupled to the cross beam 47 by an attachment system such as a plurality of bolts 50 and a base plate 51. In some embodiments, there may be some form of seal or gasket 52 located near the perimeter of the fill plates 48a and 48b where they are coupled to the horizontal rail assembly 46.

In contrast, FIGS. 1B-B illustrate a horizontal cross-sectional view of a typical vertical rail assembly 44, which vertical rail assembly 44 connects the left side of an existing infill panel 48c with the right side of an existing infill panel 48 d. In general, the vertical rail assembly 44 may include a mullion 54 and a mullion cover 56, the mullion cover 56 being coupled to the mullion 54 via an attachment system such as a plurality of bolts 50 and a base plate 51. In some embodiments, there may be some form of seal or gasket 52 positioned near the perimeter of the filler plates 48c and 48d where they couple to the vertical rail assembly 44.

The infill panel 48 may be any type of vision, spandrel or shadow box glass infill panel or any type of metal clad infill panel. The panel 48 may be any type of unitary, laminated, double-sided, triple-sided, or multi-sided panel of any configuration, or any other type of glass-filled panel.

The prior art glass system 40 shown in FIGS. 1, 1A-A, and 1B-B is merely exemplary and is not intended to limit the scope of the present invention in any way. The present invention may be readily used with a variety of new and existing glazing systems including, but not limited to, single, double or multiple pane glazing systems, mechanical or structural glazing systems, fixed point glazing systems, component and integral curtain walls, window walls, fixed and operable windows, doors, skylights, bevel glass, and the like.

Overview of the glass cover system:

FIG. 2A is an isometric view illustrating one embodiment of a glass enclosure system 100 mounted on a filler plate, such as the existing filler plate 48 of the glass system 40 shown in FIG. 1 discussed above. Fig. 2B is an exploded view of the glass cover system 100, the glass cover system 100 generally including a support frame 102 and a composition plate 104. In certain embodiments, the glass cover system 100 may be mounted to existing filler plates 48 in a non-invasive and non-destructive manner. In certain embodiments, the support frame 102 may be attached to the infill panel 48 using a peripheral attachment device or mechanism, such as a structural adhesive applied to one surface of the peripheral region of the infill panel 48, as will be explained later.

Instead, the compoboard 104 may be mounted to the support frame 102 by engagement with one or more mechanical mechanisms as described below. In certain embodiments, when the multipacks 104 are mounted to the support frame 102 (which is in turn mounted to the existing infill panel 48), a quantity of air is then trapped between the infill panel 48 of the existing glass system 40 and the multipacks 104 of the present disclosure, thereby forming an insulated glass enclosure.

A support frame:

turning to fig. 3A, an isometric view of the support frame 102 of the glass cover system 100 is shown. In one embodiment, the support frame 102 includes a top rail assembly 110, a bottom rail assembly 112, and first and second side rail assemblies 114, 116. The top, bottom and side rail assemblies 110, 112, 114, 116 further include a top rail member 111, a bottom rail member 113, a first side rail member 115 and a second side rail 117, respectively. In one embodiment, the top, bottom and side rail members 111, 113, 115, 117 may be made of extruded metal, such as aluminum. In alternative embodiments, the top, bottom and side rail members 111, 113, 115, 117 may be made of extruded composite or polymer-based materials, such as vinyl, polyvinyl chloride (PVC) or unplasticized polyvinyl chloride (uPVC), for better thermal performance. Additional metal pieces or extrusions may be used with the composite or polymer-based profile to achieve better bonding and structural performance.

In some embodiments, rail members, such as rail members 115 and 117, may have multiple openings. Some of the openings, such as opening 158, are designed to engage a series of protrusions (not shown), which may help couple the compoboard 104 to the support frame 102, as will be described below. In other embodiments, other openings, such as opening 160, are designed to reduce the overall weight of the support frame 102. In other embodiments, various components, such as control components or drying elements, may be located in the compartments and/or spaces formed by these openings 160.

Fig. 3B is a vertical cross-sectional view of a prior art horizontal rail assembly 46 of the glass system 40 shown in fig. 1A-a, with the addition of two support frames above and below the cross-beam cover 49. As shown in fig. 3B, the upper portion of the support frame 102a includes a top rail member 111 and the lower portion of the support frame 102B includes a bottom rail member 113. The top rail member 111 is shaped to include an interconnecting or anchoring means, which in some embodiments may include a hooked protrusion 162. Similarly, the bottom rail member 113 is shaped to include an interconnecting or anchoring means that may also include a hooked protrusion 162.

In addition to the interconnecting features, the cross-sections of the top rail member 111 and the bottom rail member 113 may be shaped to engage with other components, such as rubber grommets, connector pieces, or other components. In certain embodiments, there may be additional protrusions 163, which protrusions 163 may form cavities for the seal and/or the drying element when the system is assembled.

FIG. 3C is a horizontal cross-sectional view of a prior art vertical rail assembly 44 of the glass system 40 shown in FIGS. 1B-B, with the addition of two support frames on either side of mullion cover 56. As shown in fig. 3B, the left portion of the support frame 102c includes a side rail member 115, and the right portion of the support frame 102d includes a side rail member 117. In general, the side rail members 115 and 117 may be shaped to allow formation of a cavity or compartment for the seals and other components discussed below. Additionally, the cross-sections of the side rail members 115 and 117 may be shaped to engage with other components (e.g., rubber grommets, connector pieces) or other components (e.g., rubber grommets 130).

In one embodiment, as shown in fig. 3B and 3C, the support frame 102 may be attached to the infill panel 48 using a peripheral attachment device or mechanism. For example, a structural adhesive may be applied to the surfaces of top rail member 111, bottom rail member 113, first side rail member 115, and second side rail member 117 that will face infill panel 48. As described below, the rail members forming the support frame 102 may then be pressed against the existing infill panel 48, which in turn will cause the structural adhesive to engage the peripheral region of the infill panel 48. Thus, the support frame 102 would then be coupled to the peripheral region of the fill plate 48.

A wide variety of peripheral attachment devices (e.g., structural adhesives) may be used to couple the support frame 102 to the infill panel 48. In one embodiment, a structural adhesive seal 126, such as Dow

Structural silicone sealant can be applied in situ to the top, bottom and

side rail members

111, 113, 115 and 117. Additionally, one or more double-sided peripheral adhesive tape 124 may be applied to the top, bottom and

side rails

111, 113, 115, 117 in the shop or field to define an area for structural adhesive seals 126 and to secure the rails in placeAs a means of temporary attachment until the structural adhesive seal 126 is fully cured and ready to carry the load of the assembled system.

In one embodiment, one or more of the double-sided peripheral tape 124 may be a polyisobutylene or butyl glass tape for lower water vapor transmission rate ("WVTR"), and/or a structural tape for higher initial load resistance. Rubber grommets 128 may be used to cover the exposed face of the tape as well as the top, bottom and side rails 111, 113, 115, 117.

In an alternative embodiment, as shown in FIG. 4D, a program such as

Double-sided structural tape 166, such as VHB tape, applied in the shop or on-site, replaces the structural adhesive seal 126, as well as replacing the double-sided adhesive tape 124 associated with one or all of the top, bottom and

side rail members

111, 113, 115, 117, or only the double-sided adhesive tape 124 associated with one or all of the

side rail members

115, 117. It should be noted that the dimensions of the structural adhesive elements are merely exemplary and are not intended to limit the scope of the present disclosure. Generally, their size is determined by case structure calculation.

Returning to fig. 3B and 3C, in certain embodiments, a gap 129 may be formed at the periphery of the glass cover system 100. A portion of the gap 129 shown for the support frame 102a is formed between the upper profile member 111 and the cross-beam cover 49. A similar portion of the gap 129 shown for the support frame 102b is formed between the lower profile member 113 and the cross-beam cover 49. The gap 129 provides dimensional tolerances and allows for mounting, plate movement, and thermal expansion. In an embodiment, the gap 129 may be set/defined using standard or custom spacing tools or removable mounting caps coupled to the support frame 102. In one embodiment, a dry seal such as a rubber gasket 130 may be used on the outer periphery of the support frame 102 to fill the gap 129 and form a rear air and water barrier at the periphery of the support frame 102. In an alternative embodiment, the wet seal 131, which may be used in the field after installation of the support frame 102, may replace the rubber grommet 130 (as shown in fig. 4D) and may provide additional structural support. In certain embodiments, the wet seal 131 may be a butyl rubber caulk for lower WVRT. In some embodiments, one or more spacers or shims (not shown) may be used below the bottom rail assembly 112 for additional structural support.

Combining the plates:

fig. 4A is a partially cut-away isometric view of an exemplary composite deck that may be used with the present system 100. The composite panel 104, which may be pre-assembled at a shop floor or manufacturing facility, includes a cell frame 132 and a filler panel 134. In certain embodiments, as shown in fig. 4A, cell frame 132 includes top profile member 144, bottom profile member 146, and side profile members 148, 150. In an embodiment, the cell frame 132 (and its profile members) may be made of extruded metal, such as aluminum. In an alternative embodiment, the profile member may be made of an extruded composite or polymer-based material, such as polyvinyl chloride (PVC) or unplasticized polyvinyl chloride (uPVC), to achieve better thermal performance. In such embodiments, additional metal pieces or extrusions may be used with the composite or polymer-based profile members for better adhesive bonding and structural performance.

The infill panel 134 may be any type of vision, spandrel, shadow box, or overlay infill panel. The filler plate 134 may be made of a single or composite material, including but not limited to glass, polymer-based materials such as acrylic or polycarbonate, or metals such as aluminum. In one embodiment, the filler sheet 134 may be a single sheet of single or laminated glass, unitary glass sheet of any type or configuration. In another embodiment, the filler panel 134 may be an insulating glass unit having two or more layers of any type or configuration, including a vacuum insulating panel. The fill sheet 134 may be a transparent, translucent, micro-transparent, or opaque fill sheet.

In certain embodiments, the filler sheet 134 may incorporate one or a combination of any type of film and/or coating, including but not limited to solar control films, Polymer Dispersed Liquid Crystal (PDLC) films, hard (sputtered) or soft (pyrolytic) coatings, such as metal oxide coatings, low emissivity coatings, electrochromic coatings, thermochromic coatings, photovoltaic coatings, and the like.

FIG. 4B is a vertical cross-sectional view of a prior art horizontal rail assembly 46 of the glass system 40 shown in FIG. 3B, with the addition of two combination plates above and below the cross beam cover 49. Two assemblable plates 104a and 104b are positioned adjacent and shown mated with the support frames 102a and 102 b.

FIG. 4D is also a vertical cross-sectional view of the prior art horizontal rail assembly 46 of the glass system 40 shown in FIG. 3B, with the addition of two combination plates above and below the cross beam cover 49. Two assemblable plates 104a and 104b are positioned adjacent and shown mated with the support frames 102a and 102 b. The embodiment shown in fig. 4D is conceptually similar to the embodiment shown in fig. 4B, but the embodiment of fig. 4D shows alternate details that will be discussed below.

As shown in fig. 4B and 4D, the upper portion of the doubler plate 104a includes a top profile member 144. Top profile members 144 are shaped to cooperate with the interconnecting or anchoring means of top rail members 111. Specifically, in one embodiment, the top profile member 144 includes an inverted hook-like projection 164, the inverted hook-like projection 164 being sized and shaped to engage and fit within the hook-like space created by the projection 162 of the top rail member 111. In addition to the interconnecting features, the cross-section of top profile member 144 may be shaped to engage with other components, such as rubber washers (e.g., rubber washer 152 and rubber washer 154 of the embodiment shown in fig. 4B), connectors, or other components.

Similarly, the bottom profile member 146 of the compoboard 104b may be shaped to mate with the interconnecting or anchoring means of the bottom rail member 113. For example, the bottom profile member 146 includes an inverted hook-like projection 164, the hook-like projection 164 being sized and shaped to engage and fit within the space created by the hook-like projection 162 of the bottom rail member 113. In addition to the interconnecting features, the cross-section of bottom profile member 144 can be shaped to engage with other components, such as rubber gaskets (e.g., rubber gasket 152 and rubber gasket 154 of the embodiment shown in fig. 4B), connectors, or other components.

FIG. 4C is a horizontal cross-sectional view of a prior art vertical rail assembly 44 of the glass system 40 as shown in FIG. 3C with the addition of two assemblable plates on either side of the mullion cover 56. As shown in FIG. 4C, the left side portion 104C of the compoboard includes a first side profile member 148 and the right side portion 104d of the compoboard includes a second side profile member 150. The cross-section of first side profile member 148 and second side profile member 150 may be shaped to engage with other components, such as rubber grommets (e.g., rubber grommets 152), connectors, or other components. Note that when first side profile member 148 is positioned adjacent side rail member 115, a cavity or compartment 168 may be formed. Similarly, when second side profile member 150 is positioned adjacent side rail member 117, a cavity or compartment 168 may be formed on the opposite side of mullion cover 56.

Returning to fig. 4A-4D, in one embodiment, as shown in fig. 4B and 4C, the filler plate 134 may be structurally mounted to the cell frame 132 (e.g., profile members 144, 146, 148, and 150) using a structural adhesive seal 138 or a structural tape 139 as shown in fig. 4D, and one or more continuous glass tapes 136 and/or one or more spacers (not shown). The one or more continuous glass tapes 136 can be polyisobutylene or butyl glass tapes for lower WVTR. In an alternative embodiment, the fill plate 134 may be mechanically mounted to the cell frame 132 using conventional methods currently known in the art. As shown in fig. 4B-4D, in one embodiment, the filler panel 134 may be a laminated glass panel with steps between the panels comprising the laminate such that the composite panel 104 will extend to the outer edge of the cell frame 132 and have a frameless appearance. In an alternative embodiment, the composite panel 104 may have exposed frame edges, wherein the cell frame 132 may be exposed or covered by a wet or dry seal.

In one embodiment, a dry seal, such as a rubber gasket 152, may be used on the outer periphery of the compoplate 104 to fill the gap 129 and form a front air and water barrier around the periphery of the compoplate 104. The rubber gasket 152 may be generally grooved around the existing vent hole 57 (see fig. 4B and 4D). In some embodiments, the rubber gasket 152 may be chamfered at the corners and may be integrally bonded. In an alternative embodiment, a wet seal such as a butyl rubber caulk may be substituted for the rubber gasket 152 for lower WVTR and may be applied around the periphery after installation of the composition plate 104 (without blocking the existing vent holes 57).

In one embodiment, once the multipacks 104 are mounted on the support frame 102, a continuous double-sided tape 137 (see fig. 4D) having a low WVTR, such as polyisobutylene or butyl glass tape, may be applied to the unit frame 132 in the shop or on-site to form a continuous water vapor barrier around the periphery between the support frame 102 and the multipacks 104. Additionally, for lower WVTR, wet seals (not shown), such as butyl rubber caulk, may be applied in the shop at the corners where the top, bottom and side profile members 144, 146, 148 and 150 of the unit frame 132 meet.

In certain embodiments, the unit frame 132 may include a drying element 140 to help reduce the likelihood of condensation forming on surfaces adjacent to the newly formed air gap 142. In one embodiment, the dry element 140 may be a warm spacer of silicone foam substrate with dry pre-filler and pre-applied side glue for adhesion, such as QuantexSuper Spacers. In certain embodiments, such as the embodiment shown in fig. 4D, additional drying elements 141 (e.g., metal, composite, or polymer-based spacers filled with a drying material such as molecular sieves) may be added to the cell frame 132 at the shop or on-site using, for example, double-sided tape, such as butyl glass tape, to further help remove any residual moisture in the newly formed air gap 142 and increase the overall drying capacity in the glass cover system 100.

The engagement of the hook-like projections 164 of the top and bottom profile members 144, 146 with the hook-like projections 162 of the top and bottom rail members 111, 113 prevents the gang plate 104 from moving and disengaging from the support frame 102 on an axis perpendicular to the plane of the gang plate 104. Additionally, the side profile members 148, 150 of the cell frame 132 may incorporate one or more protrusions 156 (see fig. 4A). One or more of the protrusions 156 may have a linear shape for additional static load support or a hook shape for additional static and dynamic load support (see fig. 4E).

FIG. 4E is a cross-sectional view of one embodiment of a lower portion of the composition plate 104. In fig. 4E, it can be seen that the hooked protrusion 156 extends away from and perpendicular to the side profile member 148. When the compoboard 104 is mounted on the support frame 102, the one or more protrusions 156 will pass through corresponding openings 158 (see FIG. 3A) defined in the side rails 115, 117 of the support frame 102. Once the combo plate 104 is tucked into place, the hooked protrusion 156 will engage a portion of the support frame 102. Thus, the hook shape allows the composition board to be "locked" in place horizontally relative to the support frame 102.

In other embodiments, one or more of the projections 156 may be any shape and may simply enter the corresponding opening. For example, if the opening 158 is L-shaped as shown in FIG. 3A, the one or more protrusions 156 will initially pass through the longer vertical leg, but then be positioned so that they are located in the shorter leg of the opening 158 to prevent the compoboard 104 from moving vertically and disengaging from the support frame 102. In certain embodiments, the top profile members 144 and the bottom profile members 146 of one or more cell frames 132 may also incorporate rubber washers 154 (see FIG. 4B) having a relatively low compression set or high stiffness to further add additional resistance to independent vertical movement of the composite panel 104. In an alternative embodiment, a linear spring-like element may be substituted for the rubber washer 154. In alternative embodiments, fasteners, locking handles, or latches known in the art may alternatively or additionally be used to lock the gang plate 104 in place.

Exemplary method of installation

The cover glass system 100 may be installed on the outside or inside of an existing glass system. In certain embodiments, one or more support frames 102 may be attached to clean an existing infill panel 48 of an existing glass system 40. See, for example, fig. 1, 3B, and 3C. In an alternative embodiment, the support frame 102 may be attached to the frame of an existing glazing system. In such an embodiment, the structural adhesive would be applied to the clean surface of the frame surrounding the existing infill panel. In such embodiments, for purposes of the present disclosure and claims, the frame surrounding the existing infill panel may be considered to be a peripheral region of the infill panel and a portion of the infill panel itself.

In certain embodiments, as shown in FIG. 5, the support frame 102 may be installed in blocks or in a plurality of smaller components that may be assembled on-site or pre-assembled in a shop or manufacturing facility. In alternative embodiments, the support frame 102 may be installed as a unit in its entirety, which may be assembled on site or preassembled in a workshop or manufacturing facility.

Fig. 5 is an exploded isometric view of a support frame 102 positioned adjacent to a prior art fill plate 48. In the embodiment shown in FIG. 5, the support frame 102 is shown exploded into various components or assemblies, and one method of assembly is shown.

In one embodiment as shown in fig. 5, the support frame 102 may be installed in a separate smaller assembly, the top rail assembly 110 and/or the bottom rail assembly 112 may be installed first, and then the side rail assemblies 114, 116 may be partially installed, while allowing the other top rail assembly 110 and/or the bottom rail assembly 112 to be properly positioned relative to the side rail assemblies 114, 116 and fully installed prior to fully installing the side rail assemblies 114, 116 (i.e., connecting to the fill plate 48). In an embodiment in which a structural adhesive seal 126 is utilized (see fig. 4B), the support frame 102 may be installed by applying the structural adhesive seal 126 to the area defined by the double-sided tape 124; stripping off the polymeric liner (poly-liner) from the tape 124; the support frame 102 is then attached to the fill plate 48 after cleaning and preparing the peripheral region of the fill plate 48, as dictated by the manufacturer of the structural adhesive seal, and applying an appropriate temporary pressure, e.g., about 15PSI or higher.

In an alternative embodiment, where structural adhesive tape 166 is utilized (see fig. 4D), the support frame 102 may be installed by peeling off the polymeric facing on the structural adhesive tape 166 and then attaching the support frame 102 to the fill board, and then after cleaning and preparing the peripheral region of the fill board 48-as indicated by the manufacturer of the structural adhesive seal-attaching the support frame 102 to the fill board 48 and applying an appropriate temporary pressure, for example, about 15PSI or higher.

In one embodiment, top and bottom hook connectors 118, 120 (see fig. 3B and 5) may be added to the side rails 115, 117 using, for example, double-sided structural tape 122 to connect the side rail assemblies 114, 116 to the top and bottom rail assemblies 110, 112 and allow the support frame 102 to work as a unit. In an embodiment, a wet seal (not shown, such as butyl rubber caulk) may be applied to the support frame 102 in the field, for a lower WVTR, at region 153 (see fig. 5) where the top rail 111 and bottom rail 113 intersect the side rails 115, 117, prior to installing the side rail assemblies 114, 116 and connecting the side rail assemblies 114, 116 with the top rail assembly 110 and bottom rail assembly 112 at region 153. In an embodiment, wet seals 155 (see fig. 5) may be applied to the top rail 111 and the bottom rail 113 in the shop or on-site, except that the connectors 118, 120 may be installed at the top rail 111 and the bottom rail 113, to easily guide the installation of the side rail assemblies 114, 116 to the correct position relative to the top rail assembly 110 and the bottom rail assembly 112.

An additional installation step is to install the prefabricated composite panels 104 onto a support frame 102, which in some embodiments may capture a quantity of air and create an insulating air gap 142 (see fig. 4B, 4C, and 4D) between the fill sheets 48 of the existing glass system 40 and the composite panels 104 of the glass cover system 100. To couple the gang plate 104 to the support frame 102, one or more workers may plug and push the gang plate 104 toward the upper right corner of the support frame 102 until the hook-shaped projections 164 of the top and bottom profile members 144, 146 of the gang plate 104 rest inside the top and bottom rail members 111, 113 of the support frame 102 and the projections 156 rest inside their associated openings 158.

Next, one or more workers may lower the gang plate 104 until the hook projections 164 of the top and bottom profile members 144, 146 of the gang plate 104 rest within the spaces formed by the hook projections 162 of the top and bottom rail members 111, 113 of the support frame 102, and the projections 156 rest and hook within the bottom edges of their associated openings 158, thereby allowing the support frame 102 to carry the gang plate 104. One or more workers may then jam the gang plate 104 to the worker's left until the protrusion 156 hits the edge of its associated opening 158 and prevents further movement of the gang plate 104.

When attaching the support frame and installing the composite panels, existing exterior wall access systems, such as window wash decks or building maintenance units, may be used without the need for additional scaffolding or custom installation platforms. In some embodiments, the composite sheet 104 may also incorporate polyethylene polymer facings, waxed paper and/or other polymer-based protective layers that may be removed prior to installation of the composite sheet, which may be used to protect another adhesive side of the double-sided adhesive tape 137; the drying elements 140, 141 should be protected from moisture wetting prior to installation of the composite panel 104; and keeps the surfaces of the filler plate 134 adjacent the air gap 142 clean until the compoboard 104 is installed.

In some embodiments, the following manufacturing may be generally performed using an extrusion method: of the top, bottom and side rail members 111, 113, 115, 117 of the support frame 102; the top, bottom and side profile members 144, 146, 148, 150 of the composite deck 104; and connectors 118, 120. In one embodiment, after extruding the profile members, the top, bottom and side rail members 111, 113, 115, 117 of the support frame 102 may be cut to length using 90 degree angles, while the top, bottom and side profile members 144, 146, 148, 150 of the unit frame 132 may be cut to length using 45 degree angles. The protrusion 156 may then be trimmed/cut using a saw blade and/or a Computer Numerical Control (CNC) machine, and the cuts, openings, such as openings 158, 160, etc., may be formed using the CNC machine.

Active (Intelligent) embodiment

In certain embodiments, the compoboard 104 may be an active, self-sufficient board that is capable of converting absorbed light into electrical energy, storing it in an incorporated energy storage device, and powering one or more built-in devices and/or systems in the compoboard 104, which may then be used to control the group 104 via a built-in control system that has power and communication capabilities, including wireless capabilities.

FIG. 6A is a detailed horizontal cross-sectional view at an existing vertical rail assembly 44, illustrating one embodiment of a system 100 incorporating various components of a "smart" window or "smart" system. In the embodiment shown in fig. 6A, the filler sheet 134 may be a unitary glass sheet with two or more layers (e.g., a proximal or outer layer 202 and a distal or inner layer 204). The layers 202 and 204 may comprise glass or polymer-based substrates, and may be laminated using one or more intermediate layers 206, such as polyvinyl butyral (PVB). In certain embodiments, the filler panel 134 may incorporate one or more Photovoltaic (PV) cells or cell systems. As used in this disclosure, the term "cell" may incorporate one or more films and/or coatings known in the industry that operate substantially similar to solar cells. For example, as used in this disclosure, the term PV cell may include transparent/substantially transparent PV coatings, e.g.

PV coating or UbiquitousThe wavelegth-selective PV coating, or it may comprise a multi-layer combination of several layers or coatings to convert light into a voltage, as is well known in the art. In certain embodiments, the PV cells 208 may be applied to one of the layers of the filler sheet 134, such as on the distal surface of the outer layer 202.

Additionally, the infill panel 134 may incorporate one or more Electrochromic (EC) layers or layer systems 210. The term "layer" as used in this disclosure may include one or more films and/or coatings, which may be a conductive layer having a light transmittance that varies with current, such as View

An electrochromic coating. The EC layer 210 may be applied to one of the other layers of the infill panel 134, such as on the proximal surface of the inner layer 204. Additional coatings and/or films may also be incorporated between the various layers of the filler board 134 and/or applied to the proximal surface of the outer layer 202 or the distal surface of the inner layer 204.

PV cell 208 may incorporate one or more transparent electrodes that connect the one or more layers of photovoltaic coating to control system 220 using wires or leads 212 that pass through one or more cutouts 179 in the side profile members (e.g., profile members 150) of cell frame 132. Additionally, one or more EC layers 210 may incorporate one or more electrical connections (not shown), such as bus bars, that connect the electrochromic coating to a control system 220 using wires 212 that pass through one or more cutouts 179 in the side profile members (e.g., side profile members 150) of the cell frame 132.

In one embodiment, the cell frame 132 may also incorporate a light source, such as a linear Light Emitting Diode (LED) lighting strip 214, which may be connected to the control system 220 using wires 212 in the side profile members (e.g., profile members 150) of the cell frame 132 that pass through the cutouts 179.

In one embodiment, the control system 220 and the energy storage device 216, e.g., a battery, in communication with the control system 220 may be attached to the side profile members 148, 150 of the unit frame 132 using, e.g., double-sided adhesive tape 181 and positioned such that it passes through the opening 160 and fits within the cavity 168 defined by the side rail members 117 of the support frame 102, while leaving a tolerance gap for moving/mounting the gang plate 104 to the support spacer 102.

Fig. 6B is a functional diagram of one intelligent embodiment that may be included in the system 100 including the control system 220. As shown in fig. 6B, the control system 220 may be in communication with the PV cells 208, the EC layer 210, the LED lighting strip 214, and the energy storage device 216.

FIG. 6C is a functional diagram of one embodiment of a control system 220. In certain embodiments, the control system 220 may incorporate one or more circuit boards, cards or chips that may incorporate one or more microcontrollers/processors 221, the microcontrollers/processors 221 including appropriate logic (in memory 228, see fig. 6C) for performing one or more power and/or communication control functions, with appropriate logic possibly combined in one circuit board, card or chip. Additionally, the control system 220 may include a power management unit 230, the power management unit 230 directing electrical energy generated by the PV cells 208 to charge the energy storage device 214 for later use and/or to directly provide current to control/power built-in electronics, devices, and/or systems in the combi-board 104, including but not limited to the control system 220, the EC layer 210, and the LED lighting strips 214.

In certain embodiments, the control system 220 may also incorporate a boost/DC-DC converter 232 to boost the voltage of the Direct Current (DC) provided by the PV cells 208 to a suitable level for utilization within the system, including Maximum Power Point Tracking (MPPT), to maximize power extraction from the PV cells 208 under all conditions. The control system 220 may also incorporate a power converter 234 to convert the low voltage to the power requirements of the EC layer 210 and one or more driver circuits 236 to feed power to the EC layer 210.

In certain embodiments, the control system 220 may also incorporate one or more communication units 226 in communication with the one or more processors 221, and the one or more communication units 226 are used to receive and transmit commands wirelessly with the control system 220 and one or more remote controllers 218 (e.g., user interfaces and/or building automation systems). A computer-readable medium, such as the memory 228, in communication with the one or more processors 221 may be used to store such commands and may store other system information about the composition board 104 in a configuration file. In some embodiments, there may also be radio frequency identification tags (RFIDs) that incorporate system information into the configuration file. For example, the communication unit 226 may include a radio broadcasting device for wireless control (such as RF and/or IR) and a wireless communication device such as bluetooth, WiFi, Zigbee, EnOcean to send instructions to the processor 221 and data to the building automation system.

The control system 220 may also incorporate one or more on-board sensors 222, such as thermal sensors, in communication with the processor 221. In addition, the control system 220 may communicate with one or more sensors 223 (e.g., optical sensors) that are remote and/or incorporated into the frame via the signal conditioning module 224 and/or via the communication circuitry 226.

In certain embodiments, the color level of one or more EC layers 210 is determined from the output of one or more remote controls 218 or one or more sensors 223 to control system 220 based on various information from the configuration file in memory 228. The one or more processors 221 may then instruct the power management unit 230 to apply a voltage and/or current to the EC layer 210 to transition to a desired color level. In some embodiments, the control system 220 may also be configured with a user interface, such as when automation is not required, so that it may serve as an end user I/O controller, e.g., a keyboard or other user controlled interface for end users to control EC layer functions and/or other functions related to other built-in devices/systems in the combo board 104.

In still other embodiments, the control system 220 may incorporate one or more wireless power transmitters and/or receivers for wireless power functionality, which may be used to power one or more electronic devices and/or systems within the combi-plate 104 or transmit the power generated by the PV cells 208 for use with other devices that are tightly incorporated on the combi-plate 104. Wireless power transfer includes, for example, but is not limited to, induction, resonance induction, radio frequency power transfer, microwave power transfer, and laser power transfer. It should be noted that although the embodiments are described as retrofit systems for use with existing glass systems, those skilled in the art will appreciate that these embodiments or glass cover portions thereof may also be provided as new and improved integral parts or alternatives to glass systems. For example, the removable compoboard 104 and its associated mounting mechanism may be readily incorporated into the frame of a new glass system such that it includes a removable insulated glass cover to protect and reinforce the non-removable primary glass system.

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

The foregoing descriptions of embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many combinations, modifications, and variations are possible in light of the above teaching. For example, in certain embodiments, each of the above-described components and features may be combined with other components or features, either individually or sequentially, and still be within the scope of the present invention. Undescribed embodiments having interchangeable parts are still within the scope of the invention. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.

The claims (modification according to treaty clause 19)

1. A system for retrofitting an existing glass system, comprising:

a support frame comprising:

an upper stop member having first means for interconnecting,

a lower rail member having a second means for interconnecting,

a first side rail member connecting the upper rail member to the lower rail member,

a second side rail member connecting the upper rail member to the lower rail member,

a peripheral attachment device for coupling the support frame to an existing infill panel of existing glass,

a composition plate removably coupled to a support frame, the composition plate comprising:

a unit frame comprising:

a head profile member shaped to cooperate with first means for interconnection,

a sill profile member shaped to cooperate with a second means for interconnection,

a first mullion member connecting a head section member to a sill section member,

a second mullion member connecting the head section member to the sill section member,

a filler board coupled to the unit frame, and

an attachment device coupling the infill panel to the cell frame.