CURTAIN WALL INSULATION SYSTEM WITH IMPROVED BACK PAN

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and any benefit of U.S. Provisional Application No. 63/567,974, filed Mar. 21, 2024, the content of which is incorporated herein by reference in its entirety.

FIELD

The general inventive concepts relate to insulation systems for inhibiting a fire from moving between adjacent floors of a building and, more particularly, to a system for insulating a curtain wall structure that includes an improved back pan, as well as an insulated curtain wall component that includes the improved back pan.

BACKGROUND

Curtain wall insulation systems are commonly used to insulate adjacent floors of buildings that include curtain wall structures. In particular, the curtain wall insulation systems are used to provide thermal insulation and to inhibit the spread of fire from one floor to an upper adjacent floor through perimeter voids between an edge of a floor slab and the exterior building structure, which is sometimes referred to as the safing slot area.

A curtain wall structure is a non-load bearing type of exterior wall system that is utilized on buildings, such as high-rise buildings. The curtain wall structures generally utilize lightweight materials and often include metal skins. Conventional curtain wall structures include vertical framing members, referred to as mullions, and horizontal framing members, referred to as transoms. The mullions and transoms are typically hollow box-shaped members formed of aluminum. Curtain wall structures also include spandrel panels to provide an exterior facing thereof and are commonly made of glass (e.g., vision glass, opaque glass), aluminum, stone, thin sheets of foam material, and the like.

Curtain wall structures and insulation systems may also include an interior panel, commonly referred to as a back pan, that spans the area between the mullions and transoms and serves as a vapor barrier. One example of a system 10 for insulating a curtain wall structure 50 that includes a back pan 70 is illustrated in FIG. 1. As seen in FIG. 1, the curtain wall structure 50 is spaced from a floor slab 60 of the building structure (not shown) to define a perimeter void 65. The curtain wall structure 50 includes framing defined by at least first and second vertically disposed and parallel mullions 51, 52, and at least first and second horizontally disposed transoms 53, 54. In addition, the curtain wall structure 50 includes at least one spandrel panel 55 and at least one vision glass 56 connected to the mullions 51, 52 and transoms 53, 54. As seen in FIG. 1, a back pan 70 is attached to the interior surface of the mullions 51, 52 and transoms 53, 54. The system also includes reinforcing members 71, 72 that extend between the mullions 51, 52 and that are attached to the back pan 70 such that a horizontal leg 71a of reinforcing member 71 is positioned 2 inches (5.08 cm) below a top surface of floor slab 60 and a horizontal leg 72a of reinforcing member 72 is positioned 6 inches (15.24 cm) below the top surface of floor slab 60. The system also includes a curtain wall insulation 80 that is positioned between the spandrel panel 55 and the back pan 70. The curtain wall insulation 80 is scored to receive the horizontal legs 71a, 72a of reinforcing members 71, 72 and is friction fit between the mullions 51, 52 and transoms 53, 54 and abuts against the back pan 70. The curtain wall insulation 80 is secured to the back pan 70 using cup head weld pins (not shown). As seen in FIG. 1, the system also includes safing insulation 90 that is disposed within the perimeter void 65 and is compression fit between the back pan 70 and the floor slab 60. The system also includes a smoke sealant 92 that is applied atop the safing insulation 90, as well as mullion cover insulation 95 that is attached to mullions 51, 52.

Back pans utilized in conventional curtain wall structures and insulation systems are generally formed from sheets of galvanized steel. Although the back pans do not melt when exposed to fire/heat (e.g., temperatures below approximately 1,500° C.), the back pans will tend to buckle or warp due to expansion and contraction when exposed to fire/heat. The deformation of the back pan creates gaps or seams between the back pan and the safing insulation that permit the passage of fire and smoke from one floor to the next. As a result, conventional curtain wall structures and insulation systems that utilize back pans, such as the system shown in FIG. 1, also typically incorporate reinforcing members to prevent the back pan from buckling or warping. However, the reinforcing members contribute additional material costs to the system, as well as additional labor for installation. Furthermore, attaching the reinforcing members to the back pan creates penetrations through the back pan that compromise its vapor barrier functionality, which can lead to moisture issues and costly repairs.

Accordingly, there is an unmet need in the art for an improved system for insulating a curtain wall structure that utilizes a back pan but does not require conventional reinforcing members or the accompanying attachment penetrations through the back pan that compromise its vapor barrier functionality.

SUMMARY

The general inventive concepts relate to and contemplate a system for insulating a curtain wall structure that includes a back pan, as well as an insulated curtain wall component that includes a back pan. The system and insulated curtain wall component include a back pan having an improved design such that no separate reinforcing members are required to be attached to the back pan and, thus, no additional penetrations are made through the back pan. Accordingly, the system and insulated curtain wall component of the present disclosure include fewer parts, thereby reducing material costs and installation costs, while also retaining the vapor barrier functionality of the back pan. To illustrate various aspects of the general inventive concepts, several exemplary embodiments of insulating systems, back pans, and insulated curtain wall components are disclosed.

In accordance with one aspect of the present disclosure, a system for insulating a curtain wall structure connected to a building structure is provided. The curtain wall structure is spaced from a floor slab of the building structure to define a perimeter void. The curtain wall structure includes framing defined by at least first and second vertically disposed and parallel mullions and at least first and second horizontally disposed and parallel transoms, which are separated by a transom distance. The system includes a back pan interfaced with the framing. The back pan has an exterior facing surface, an interior facing surface, an installed length, and a material length. The installed length can be greater than or equal to the transom distance. The material length is greater than the installed length, for example, due to a flange or rib formed on the back pan. In addition, the system includes a curtain wall insulation disposed within the framing. The system also includes a safing insulation disposed within the perimeter void and compression fit between the interior facing surface of the back pan and the floor slab.

In accordance with another aspect of the present disclosure, an insulated curtain wall component is provided. The insulated curtain wall component includes framing defined by at least first and second vertically disposed and parallel mullions and at least first and second horizontally disposed and parallel transoms separated by a transom distance. In addition, the insulated curtain wall component includes a back pan interfaced with the framing. The back pan has an exterior facing surface, an interior facing surface, an installed length, and a material length. The installed length can be greater than or equal to the transom distance. The material length is greater than the installed length, for example, due to a flange or rib formed on the back pan. The insulated curtain wall component also includes a curtain wall insulation disposed within the framing.

Other aspects and features of the general inventive concepts will become more readily apparent to those of ordinary skill in the art upon review of the following description of various exemplary embodiments in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The general inventive concepts, as well as embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the drawings in which:

FIG. 1 is a perspective partial cutaway view of a system for insulating a curtain wall structure that includes a conventional back pan.

FIG. 2 is a side sectional view of an embodiment of a system for insulating a curtain wall structure having a back pan in accordance with the present disclosure.

FIG. 3 is a side elevation view of an embodiment of a back pan of the present disclosure.

FIG. 4 is a side elevation view of an embodiment of a back pan of the present disclosure.

FIG. 5 is a side elevation view of an embodiment of a back pan of the present disclosure.

FIG. 6A is a side sectional view of an embodiment of a system for insulating a curtain wall structure having a back pan in accordance with an embodiment of the present disclosure.

FIG. 6B is a side sectional view of an embodiment of a system for insulating a curtain wall structure having a back pan in accordance with an embodiment of the present disclosure.

FIG. 7 is a side sectional view of an embodiment of a system for insulating a curtain wall structure having a back pan in accordance with an embodiment of the present disclosure.

FIG. 8 is a partial side sectional view of an embodiment of a system for insulating a curtain wall structure having a back pan in accordance with an embodiment of the present disclosure.

FIG. 9 is a partial side sectional view of an embodiment of a system for insulating a curtain wall structure having a back pan in accordance with an embodiment of the present disclosure.

FIG. 10 is a partial side sectional view of an embodiment of a system for insulating a curtain wall structure having a back pan in accordance with an embodiment of the present disclosure.

FIG. 11 is a partial side sectional view of an embodiment of a system for insulating a curtain wall structure having a back pan in accordance with an embodiment of the present disclosure.

FIG. 12 is a perspective view of an embodiment of a back pan of the present disclosure.

FIG. 13 is a perspective view of an embodiment of a back pan of the present disclosure.

FIG. 14 is a front elevation view of an embodiment of an insulated curtain wall component of the present disclosure.

FIG. 15 is a cross sectional view of the insulated curtain wall component of FIG. 14, taken along section line A-A.

DETAILED DESCRIPTION

Several illustrative embodiments will be described in detail with the understanding that the present disclosure merely exemplifies the general inventive concepts. Embodiments encompassing the general inventive concepts may take various forms and the general inventive concepts are not intended to be limited to the specific embodiments described and illustrated herein.

The general inventive concepts relate to systems for insulating a curtain wall structure connected to a building structure, as well as to insulated curtain wall components that are prefabricated off-site prior to being installed at a construction site. The systems and insulated curtain wall components include an innovative back pan in combination with curtain wall insulation and safing insulation to effectively insulate a curtain wall structure and provide perimeter firestop protection. The back pan is configured such that separate reinforcing members, such as the reinforcing members 71, 72 used in the system 10 shown in FIG. 1, are not required to be attached to the back pan to achieve a flame rating (“F rating”) of at least 2 hours (as measured in accordance with ASTM E2307: Standard Test Method for Determining Fire Resistance of Perimeter Fire Barrier Systems Using Intermediate-Scale, Multi-story Test Apparatus). Accordingly, the system and insulated curtain wall component of the present disclosure include fewer parts, thereby reducing material and installation costs, while also retaining the vapor barrier functionality of the back pan by avoiding attachment penetrations and achieving an acceptable F rating.

An embodiment of a system 100 for insulating a curtain wall structure 150 in accordance with the present disclosure is shown in FIG. 2. The system 100 is useful for insulating a curtain wall structure 150 connected to a building structure (not shown), as well as providing perimeter firestop protection. As one of skill in the art will appreciate, a curtain wall structure 150 is a type of exterior wall system commonly used on buildings, such as high-rise buildings, wherein the curtain wall structure 150 does not bear the load of the building structure. As seen in FIG. 2, the curtain wall structure 150 is spaced from a floor slab 160 of the building structure to define a perimeter void 165. The curtain wall structure 150 includes framing defined by at least first and second vertically disposed and parallel mullions 152 (only one shown) and at least first and second horizontally disposed and parallel transoms, such as an upper horizontally disposed transom 154 and a lower horizontally disposed transom 156. The transoms 154, 156 are separated by a transom distance TD, which corresponds to the distance between a bottom surface 154a of the first transom 154 and a top surface 156a of the second transom 156. The mullions 152 and transoms 154, 156 are typically hollow box-shaped members formed of aluminum. As shown in FIG. 2, the curtain wall structure 150 also includes a spandrel panel 155 connected to the framing. The spandrel panel 155 provides an exterior fac̨ade of the curtain wall structure 150 and is commonly formed of glass, aluminum, stone, thin sheets of foam material, and the like. The system 100 provides thermal insulation and also provides a barrier to inhibit the spread of fire from one floor of a building to an upper adjacent floor through the perimeter void 165.

With continued reference to FIG. 2, the system 100 includes a back pan 170 interfaced with the framing. The back pan 170 can interface with the framing in a variety of ways. For example, the back pan 170 can be interfaced with, or otherwise joined to, the framing by mechanical fasteners (e.g., screws), by welding, or other techniques known to those of skill in the art. As previously noted, the back pan 170 functions as a vapor barrier for the system 100 by preventing or inhibiting the transmission of water vapor. The back pan 170 is typically formed of a metal or a metal alloy, although other materials that function as a vapor barrier and are otherwise suitable for use in perimeter firestop applications may be used. In certain embodiments, the back pan 170 comprises galvanized steel. In certain embodiments, the back pan 170 comprises galvanized steel having a gauge in the range of about 16 to about 26 (or a thickness ranging from about 0.47625 mm to about 1.5875 mm) or any gauge or subrange of gauges within this range. In certain embodiments, the back pan 170 comprises galvanized steel having a gauge in the range of about 16 to about 22 (or a thickness ranging from about 0.79375 mm to about 1.5875 mm) or any gauge or subrange of gauges within this range. For example, the back pan 170 can comprise galvanized steel having a gauge of about 16 or a gauge of about 22.

Now referring to FIGS. 2 and 3, the back pan 170 has an exterior facing surface 171 and an interior facing surface 172. In addition, the back pan 170 has an installed length L_I and a material length. As seen in FIG. 2, the installed length L_I corresponds to the linear length measured from a first end 173 of the back pan 170 to a second end 174 of the back pan 170. The material length (not labeled) corresponds to the length measured along the back pan 170 itself from the first end 173 to the second end 174.

In accordance with the present disclosure, the installed length L_I of the back pan 170 is greater than or equal to the transom distance TD. Thus, the installed length L_I ensures that the area between the transoms 154, 156 is covered by the back pan 170. In some embodiments, the transom distance TD can be at least about 50.8 cm or more (when the floor slab 160 is level with the bottom surface 154a of the transom 154). In some embodiments, T_D is in the range of about 52.07 cm to about 127 cm. In some embodiments, the installed length L_I of the back pan 170 is 2 cm to 8 cm greater than the transom distance T_D. In some embodiments, the installed length L_I of the back pan 170 is 5 cm to 8 cm greater than the transom distance T_D so that the first and second ends 173, 174 of the back pan 170 overlap the transoms 154, 156 by 2.5 cm to 4 cm.

In accordance with the present disclosure, the material length of the back pan 170 is greater than the installed length L_I of the back pan 170. In some exemplary embodiments, the material length results from controlled deformation of a flat metal or metal alloy sheet (e.g., a sheet of galvanized steel), such as by stamping, crimping, or corrugating techniques. By having a material length that is greater than the installed length L_I, the strength of the back pan 170 is increased as compared to a back pan having a material length that is equal to the installed length L_I, given the same material composition and thickness. Accordingly, the back pan 170 of the present disclosure has sufficient strength such that it can be utilized in the system 100 without having to attach a separate reinforcing member (such as reinforcing members 71, 72 required in the system 10 illustrated in FIG. 1) to support/reinforce a safing insulation 190 that is compression fit between the floor slab 160 and the back pan 170. This in turn reduces the number of components required in the system 100, which can reduce labor and material costs for constructing the system 100. In addition, the integrity of the vapor barrier functionality of the back pan 170 is maintained by not creating penetrations through the back pan 170 when attaching a separate reinforcing member.

In certain embodiments, the back pan 170 has a material length that is about 0.1% to about 100% greater than the installed length L_I. In certain embodiments, the back pan 170 has a material length that is about 0.5% to about 20% greater than the installed length L_I. In certain embodiments, the back pan 170 has a material length that is about 0.75% to about 10% greater than the installed length L_I. In certain embodiments, the back pan 170 has a material length that is in the range of about 1% to about 4% greater than the installed length L_I. In embodiments, the back pan 170 has a material length that is about 2% greater than the installed length L_I.

As seen in FIG. 2, in certain aspects, the back pan 170 comprises at least one interior facing rib 175 that abuts at least a portion of the safing insulation 190 and at least one exterior facing rib 176 that abuts at least a portion of the curtain wall insulation 180. In other aspects, the back pan 170 might include only one or more interior facing rib(s) 175 or only one or more exterior facing rib(s) 176. As seen in FIGS. 3-5, the ribs 175, 176 can be formed in a variety of configurations or shapes. For example, the ribs 175, 176 can be U-shaped with a curved or rounded end (as shown in FIG. 3) or V-shaped with a flat or planar end (as shown in FIG. 4). In certain aspects, and as shown in FIG. 5, the back pan 170 includes exterior facing ribs 176 that are V-shaped. It is also contemplated that the back pan 170 can include at least one interior facing rib 175 and at least one exterior facing rib 176 that have different configurations. For example, the at least one interior facing rib 175 may be V-shaped with a flat or planar end, while the at least one exterior facing rib 176 is V-shaped.

With reference to FIGS. 3-5, in certain aspects, the back pan 170 may include multiple ribs 175, 176 that repeat uniformly between the first and second ends 173, 174. As seen in FIGS. 3-5, the back pan 170 may have a pitch P, which describes the distance between adjacent repeating ribs 175, and a height H. In certain aspects, the pitch P is greater than the height H. In certain aspects, the pitch P is equal to the height H. In certain aspects, the pitch P is less than the height H.

As seen in FIG. 3, the back pan 170, in certain embodiments, includes an intumescent coating 179 applied to at least a portion of the interior facing surface 172 of the back pan 170. In certain aspects, an intumescent coating 179 is applied to the entire interior facing surface 172 of the back pan 170. In certain aspects, an intumescent coating 179 is applied to a portion of the interior facing surface 172 of the back pan 170 that, when applied in the system 100, is adjacent to the safing insulation 190. Any commercially available intumescent coating material may be used for the intumescent coating 179 that is applied to the interior facing surface 172 of the back pan 170. Examples of suitable intumescent coating material that may be used include FlameOff® fire barrier paint, which is commercially available from FlameOff Coatings, Inc. (Raleigh, North Carolina), and FireGuard® E-84 intumescent coating, which is commercially available from Shield Industries, Inc. (Woodstock, Georgia).

Turning back to FIG. 2, the system 100 of the present disclosure also includes a curtain wall insulation 180. The curtain wall insulation 180 may be formed of various materials based on a desired failure temperature of the material such as mineral wool. Such curtain wall insulation 180 is commercially available from Thermafiber, Inc. (Joplin, Missouri). The curtain wall insulation 180 may have a thickness of 2.54 cm to 20.32 cm and a density of 64 kg/m³ to 225 kg/m³. The curtain wall insulation 180 is disposed within the framing. Accordingly, the size and shape of the curtain wall insulation 180 will typically depend on the size and shape of the framing into which the curtain wall insulation 180 is being installed. In certain aspects, the curtain wall insulation 180 is mechanically attached to the framing, for example, with insulation hangers (not shown), such as Impasse® insulation hangers available from Thermafiber, Inc. (Joplin, Missouri), or by other conventional means used to mechanically attach curtain wall insulation 180 to the framing, such as impaling pins or screws. In certain aspects, the curtain wall insulation 180 is friction fit within the framing. In certain aspects, the curtain wall insulation 180 is secured to at least a portion of the exterior facing surface 171 of the back pan 170. For example, as seen in FIG. 2, the curtain wall insulation 180 may be secured to at least a portion of the exterior facing surface 171 of the back pan 170 with one or more fasteners 181 (e.g., cup head weld pins).

As shown in FIG. 2, the system 100 of the present disclosure also includes a safing insulation 190 disposed within the perimeter void 165 and compression fit between the interior facing surface 172 of the back pan 170 and the floor slab 160. The safing insulation 190 inhibits flames and hot gases from moving from one floor to an adjacent upper floor through the perimeter void 165. As with the curtain wall insulation 180, the safing insulation 190 may be formed of various materials based on a desired failure temperature of the material. In certain embodiments, the safing insulation 190 comprises mineral wool. The safing insulation 190 may have a thickness of 2.54 cm to 20.32 cm and a density of 64 kg/m³ to 225 kg/m³. Such safing insulation 190 is commercially available from Thermafiber, Inc. (Joplin, Missouri). When installed, the safing insulation 190 is typically compressed to varying degrees, but normally it is compressed to at least about 25% of its original thickness. After installation, the safing insulation 190 provides fireproof sealing of the perimeter void 165. Because the safing insulation 190 is compressed when installed, it provides some capability to expand which can seal openings or cracks that might otherwise develop in the perimeter void 165. Slight variations in the size of the perimeter void 165 due to expansion or other environmental changes are accommodated by the safing insulation 190 since it is compressed when placed in the perimeter void 165, and thus can provide an effective seal under various conditions.

In certain aspects, the system 100 is arranged such that a top surface 191 of the safing insulation 190 is separated from the bottom surface 154a of the first transom 154 by a vertical distance of at least 2.5 cm or more, such as at least about 7.6 cm or more. The system 100 may be arranged such that a bottom surface 192 of the safing insulation 190 is substantially coplanar with the top surface 156a of the second transom 156. The system 100 may be arranged such that the bottom surface 192 of the safing insulation 190 is separated from the top surface 156a of the second transom 156 by a vertical distance of at least 2.5 cm or more (e.g., at least about 7.6 cm or more). The components of the present system 100, and particularly the back pan 170, allow arrangements where the transoms 154, 156 are vertically separated from the safing insulation 190 without requiring a reinforcing member, whereas conventional systems that include a back pan and no additional reinforcing member (e.g., System No. CW-D-1044) require there to be essentially no vertical separation between the top surface of the safing insulation and the bottom surface of an upper transom member. Accordingly, the system 10 of the present disclosure provides more design freedom as opposed to conventional systems.

In certain embodiments, and as shown in FIG. 2, the system 100 also includes a mullion cover insulation 193 to cover and protect a portion of the mullion 152 from hot flames and gasses during a fire. As seen in FIG. 2, the mullion cover insulation 193 has opposed outer and inner surfaces 194, 195 and opposed top and bottom surfaces 196, 197 and is attached to the mullion 152 such that the outer surface 194 of the mullion cover insulation 193 abuts at least a portion of the interior facing surface 172 of the back pan 170 and the top surface 196 of the mullion cover insulation 193 abuts the bottom surface 192 of the safing insulation 190 and covers a portion of the mullion 152. The mullion cover insulation 193 may be attached to the mullion 152 using fasteners (e.g., screws). Although not illustrated, additional pieces of mullion cover insulation configured and installed in the same manner as the mullion cover insulation may be used to cover and protect additional mullions present in the system 100. The mullion cover insulation 193 may be formed of various materials based on a desired failure temperature of the material. In certain embodiments, the mullion cover insulation 193 comprises mineral wool. In certain embodiments, the mullion cover insulation 193 comprises mineral wool faced on an inner surface with an aluminum foil or other suitable fire resistant vapor retarder material. The mullion cover insulation 193 may have a thickness of 2.54 cm to 20.32 cm and a density of 64 kg/m³ to 225 kg/m³. Such mullion cover insulation 193 is commercially available from Thermafiber, Inc. of Joplin, Missouri.

With continued reference to FIG. 2, in certain embodiments, the system 100 includes a smoke sealant 198 applied to the top surface 191 of the safing insulation 190. Any smoke sealant material known in the art may be utilized in the system 100 of the present disclosure. Exemplary smoke sealant materials suitable for use in the system 100 of the present disclosure include, but are not limited to, Fast Tack™ Firestop Spray or Series AS200 Elastomeric Spray smoke sealant, commercially available from Specified Technologies, Inc. (Somerville, New Jersey); Smoke Sealant Compound™ smoke sealant, commercially available from Thermafiber, Inc. (Joplin, Missouri); FireDam™ Spray 200 smoke sealant, commercially available from 3 M (St. Paul, Minnesota); and TREMstop Acrylic SP smoke sealant, commercially available from Tremco Incorporated (Beachwood, Ohio). The smoke sealant 198 provides a barrier to the passage of smoke and/or hot gasses through the safing insulation 190. Further, in order to retard to the passage of smoke and/or hot gasses through the junctions between the safing insulation 190 and the back pan 170, as well as between the safing insulation 190 and the slab 160, the smoke sealant 198 may be applied to extend from 1.27 cm to 5.08 cm onto both the interior facing surface 172 of the back pan 170 and the floor slab 160. Typically, the smoke sealant 198 is applied by spraying the smoke sealant material onto the top surface 191 of the safing insulation 190.

Embodiments of a system 100 for insulating a curtain wall structure 150 in accordance with the present disclosure are shown in FIGS. 6-11. As described herein, the system 100 includes a back pan 170 having an exterior facing surface 171 and an interior facing surface 172. Furthermore, the back pan 170 comprises at least one of an interior facing rib 175 or an exterior facing rib 176.

Now referring to FIG. 6A, the back pan 170 can have a flange 177 extending from a perimeter of the exterior facing surface 171. The flange 177 can extend outwardly from the back pan 170 such that an angle between the flange 177 and the exterior facing surface 171 is greater than or equal to 90 degrees. The flange 177 includes a perimeter 178 distal to the exterior facing surface 171. The perimeter 178 has a first end 178a and a second end 178b. The first end 178a abuts the bottom surface 154a of the first transom 154, the spandrel panel 155, or a junction thereof. The second end 178b abuts the top surface 156a of the second transom 156, the spandrel panel 155, or a junction thereof. As described herein, the back pan 170 can interface with the framing in a variety of ways. For example, the back pan 170 can be joined to the framing by mechanical fasteners that extend through the flange 177 and into the framing. As seen in FIG. 6A, the back pan 170 has an interior installed length of L_I-int when viewing the interior facing surface 172; an exterior installed length of L_I-ext when viewing the exterior facing surface 171; and a material length. As seen in FIG. 6A, the interior installed length L_I-int corresponds to the linear length measured from a first end 173 of the back pan 170 to a second end 174 of the back pan 170. The exterior installed length L_I-ext corresponds to the linear length measured from the first end 178a to the second end 178b of the perimeter 178 of the flange 177 of the back pan 170. In some embodiments where the back pan 170 includes the flange 177, the material length (not labeled) corresponds to the length measured along the back pan 170 itself from the first end 178a to the second end 178b.

In accordance with the present disclosure, the exterior installed length L_I-ext is approximately equal to a transom distance T_D. Thus, the exterior installed length L_I-ext ensures that the area between the transoms 154, 156 is covered by the back pan 170. The interior installed length L_I-int is less than or equal to the transom distance T_D, thereby creating a gap between the interior facing surface 172 of the back pan 170 and either or both of the transoms 154, 156. As shown in FIG. 6A, the gap may be split into two gaps, G₁ and G₂. Gap G₁ is a gap between the first end 173 of the back pan 170 and the bottom surface 154a of the first transom. Gap G₂ is a gap between the second end 174 of the back pan 170 and the top surface 156a of the second transom 156. G₁ and G₂ may be substantially equal in size. In some embodiments, at least one of the gaps G₁ and G₂ are about ½″ (about 1.27 cm) or less, about ⅜″ (about 0.95 cm) or less, about ¼″ (about 0.64 cm) or less, about 3/16″ (about 0.48 cm) or less, about ⅛″ (about 0.32 cm) or less, about 1/16″ (about 0.16 cm) or less, etc. Similarly, an interior installed width of the back pan 170 may be less than a distance between mullions 152, thereby creating a gap between the interior facing surface 172 of the back pan 170 and either or both of the mullions 152. The aforementioned gaps between the interior facing surface 172 and the framing may bias the back pan 170 to expand toward an inside of the building due to heat from a fire. The inward expansion of the back pan 170 may close the gaps. However, since the back pan 170 is already expanding in an inward direction, the back pan 170 may continue to expand inwardly despite the gaps being closed (i.e., due to inward momentum of the back pan 170). By encouraging the back pan 170 to expand toward the inside of the building due to a fire, the back pan 170 applies increased pressure to the safing insulation 190, thereby ensuring the safing insulation does not become dislodged from the perimeter void 165.

Moreover, the interior installed length L_I-int is less than or equal to the exterior installed length L_I-ext. Accordingly, the flange 177 can extend outwardly from the back pan 170 such that the angle between the flange 177 and the exterior facing surface 171 is greater than or equal to 90 degrees.

In accordance with the present disclosure, the material length of the back pan 170 is greater than the exterior installed length L_I-ext. As described herein, the material length results from controlled deformation of a flat metal or metal alloy sheet, such as by stamping, crimping, rolling, corrugating, or the like. For example, processing a sheet of galvanized steel such that the flange 177, the interior facing rib 175, the exterior facing rib 176, or a combination thereof is included in the back pan 170 contributes to the material length being greater than the exterior installed length L_I-ext. Similarly, a portion of the material length of the back pan 170 disposed between the first end 173 and the second end 174 is greater than the interior installed length L_I-int. Including the interior facing rib 175, the exterior facing rib 176, or a combination thereof in the back pan 170 contributes to this portion of the material length being greater than the interior installed length L_I-int.

As seen in FIG. 6A, in certain aspects, the back pan 170 comprises an exterior facing rib 176 that abuts at least a portion of a curtain wall insulation 180. The exterior facing rib 176 can be substantially triangular, as shown in FIG. 6A. In some embodiments, the exterior facing rib 176 may be U-shaped or semicircular with a curved bottom or a flat bottom. The rib 176 can have a depth equal to or less than a thickness of the curtain wall insulation 180. The rib 176 can extend fully or partially through the thickness of the curtain wall insulation 180. In some embodiments, the rib 176 can extend into the curtain wall insulation 180 to a depth of about 1% to about 100% of the thickness of the curtain wall insulation. For example, the rib 176 can extend into the curtain wall insulation 180 to a depth of about 5% to about 50% of the thickness of the curtain wall insulation 180. The rib 176 can have a depth or a radius equal to or less than about 2″ (about 5.08 cm), such as about 1″ (about 2.54 cm), about ½″ (about 1.27 cm), etc. The rib 176 has a height measured from a lower end of the rib (i.e., a portion of the rib that is closer to the lower end 174 of the back pan 170) to an upper end of the rib (i.e., a portion of the rib that is closer to the upper end 173 of the back pan 170). As shown in FIG. 6B, in certain aspects, the height of the rib 176 can be equal to or approximately (+/−10%) the same as a height S of the safing insulation 190 measured from the bottom surface 192 to the top surface 191 of the safing insulation 190. The height of the rib 176 ensures that the safing insulation 190 naturally fills the (triangular) cavity formed by the rib 176 without requiring excess further compressive force that might otherwise cause the safing insulation 190 to not fill the cavity, thereby maximizing fireproofing effectiveness. The rib 176 can be formed on the back pan 170 such that the rib 176 is at least partially in line with the floor slab 160. For example, the rib 176 is at least partially disposed between a first horizontal plane coplanar with a top surface of the floor slab 160 and a second horizontal plane coplanar with a bottom surface of the floor slab 160. Further, the rib 176 can be formed on the back pan 170 such that the rib 176 is at least partially disposed between a third horizontal plane coplanar with the top surface 191 of the safing insulation and a fourth horizontal plane coplanar with the bottom surface 192 of the safing insulation 190. In other words, the rib 176 is at least partially in line with the safing insulation 190 (i.e., the rib 176 is at least partially in the same horizontal plane as the safing insulation 190). Furthermore, the rib 176 can be formed on the back pan 170 such that the rib 176 is at least partially disposed above a fifth horizontal plane that is midway between the third horizontal plane and the fourth horizontal plane. In other words, the fifth horizontal plane is positioned at about 50% of a height of the safing insulation 190. Moreover, the rib 176 can be formed on the back pan 170 such that the rib 176 is at least partially disposed below a sixth horizontal plane that is midway between the third horizontal plane and the fifth horizontal plane. In other words, the sixth horizontal plane is positioned at about 75% of a height of the safing insulation 190. It is contemplated that the rib 176 can be positioned at least partially above the top surface 191 of the safing insulation. It is further contemplated that the rib 176 can be positioned at least partially below the bottom surface 192 of the safing insulation.

In certain embodiments, and as shown in FIG. 7, interior facing rib 175 can support the safing 190. For example, the rib 175 may prevent the safing 190 from being installed too deeply in the perimeter void 165 (e.g., the top surface 191 of the safing 190 is sub-flush with a top surface of the floor slab 160). The interior facing rib 175 can be substantially triangular or V-shaped, as shown in FIG. 7. Further, the rib 175 may have a truncated point. The rib 175 can have a depth equal to or less than a thickness of the mullion cover insulation 193. The rib 175 can extend fully or partially through a thickness of the mullion cover insulation 193. In some embodiments, the rib 175 can extend into the mullion cover insulation 193 to a depth of about 1% to about 100% of the thickness of the mullion cover insulation 193. For example, the rib 175 can extend into the mullion cover insulation 193 to a depth of about 5% to about 50% of the thickness of the mullion cover insulation 193. The rib 175 can have a depth equal to or less than about 2″ (about 5.08 cm), such as about 1″ (about 2.54 cm).

Moreover, the rib 175 can be formed on the back pan 170 such that the rib 175 is at least partially in line with the floor slab 160. For example, the rib 175 is at least partially disposed between the first horizontal plane coplanar with a top surface of the floor slab 160 and the second horizontal plane coplanar with a bottom surface of the floor slab 160. Further, the rib 175 can be formed on the back pan 170 such that the rib 175 is at least partially disposed between the third horizontal plane coplanar with the top surface 191 of the safing insulation and the fourth horizontal plane coplanar with the bottom surface 192 of the safing insulation 190. In other words, the rib 175 may be at least partially in line with the safing insulation 190 (i.e., the rib 175 is at least partially in the same horizontal plane as the safing insulation 190). Furthermore, the rib 175 can be formed on the back pan 170 such that the rib 175 is at least partially disposed above the fifth horizontal plane that is midway between the third horizontal plane and the fourth horizontal plane. Moreover, the rib 175 can be formed on the back pan 170 such that the rib 175 is at least partially disposed below the sixth horizontal plane that is midway between the third horizontal plane and the fifth horizontal plane. It is contemplated that the rib 175 can be positioned at least partially above the top surface 191 of the safing insulation. It is further contemplated that the rib 175 can be positioned at least partially below the bottom surface 192 of the safing insulation.

Moreover, the rib 175 or 176 can include an upper portion and a lower portion. For example, as shown in FIG. 6A, the rib 176 can be positioned such that the lower portion of the rib 176 is disposed vertically above the bottom surface 192 of the safing insulation 190. As shown in FIG. 7, the rib 175 can be positioned such that the upper portion of the rib 175 abuts the bottom surface 192 of the safing insulation 190. Further, the rib 175 can include the lower portion such that the lower portion abuts the top surface 196 of the mullion cover insulation 193. Furthermore, a top end of the mullion cover insulation 193 may include a relief shape 197. The relief shape 197 corresponds to a shape of the rib 175 such that the mullion cover insulation 193 may be installed over the back pan 170 without the rib 175 creating a bulge, such as a bulge on the inner surface 195 of the mullion cover insulation 193. Furthermore, the upper portion and the lower portion can converge to form an angle θ of the rib 175 or 176. For example, as shown in FIG. 7, the upper portion and the lower portion of the rib 175 can form an angle θ, where θ is less than 90°. In some embodiments, θ can be about 80° or less, about 60° or less, about 45° or less, about 30° or less, etc. As shown in FIG. 6A, θ can be in the range of about 75° to about 80°, such as about 76° or about 77.5°. As shown in FIG. 7, 0θ can be about 30°.

As seen in FIGS. 8-11, ribs 175, 176 can be formed in a variety of configurations, shapes, or directions. For example, the ribs 176, 175 can be U-shaped with a curved or rounded end, as shown in FIGS. 6A, 6B, 8, and 9; rectangular-shaped, as shown by rib 175 in FIG. 10; or triangular or V-shaped, as shown by rib 175 in FIG. 7 and FIG. 11 and rib 176 in FIG. 12. Similar to sizes of U-shaped ribs and V-shaped ribs as described herein with reference to FIGS. 6A, 6B, and 7, a rectangular-shaped rib 176 can have a depth equal to or less than a thickness of the curtain wall insulation 180. The rib 176 can extend fully or partially through the thickness of the curtain wall insulation 180. In some embodiments, the rib 176 can extend into the curtain wall insulation 180 to a depth of about 1% to about 100% of the thickness of the curtain wall insulation. For example, the rib 176 can extend into the curtain wall insulation 180 to a depth of about 5% to about 50% of the thickness of the curtain wall insulation 180. The rib 176 can have a depth equal to or less than about 1″ (about 2.54 cm), such as about ½″ (about 1.27 cm). Similarly, a rectangular-shaped rib 175 can have a depth equal to or less than a thickness of the mullion cover insulation 193. The rib 175 can extend fully or partially through a thickness of the mullion cover insulation 193. In some embodiments, the rib 175 can extend into the mullion cover insulation 193 to a depth of about 1% to about 100% of the thickness of the mullion cover insulation 193. For example, the rib 175 can extend into the mullion cover insulation 193 to a depth of about 5% to about 50% of the thickness of the mullion cover insulation 193. The rib 175 can have a depth equal to or less than about 1″ (about 2.54 cm), such as about ½″ (about 1.27 cm). The rib 175 or 176 has a height measured from a lower end of the rib (i.e., a portion of the rib that is closer to the lower end 174 or the back pan 170) to an upper end of the rib (i.e., a portion of the rib that is closer to the upper end 173 of the back pan 170). The height can be equal to or less than a height S of the safing insulation 190 measured from the bottom surface 192 up to the top surface 191 of the safing insulation 190. The rib 176 can have a height such that at least a portion of an end of the safing 190 can be disposed within a void formed by the rib 176. The rib 175 or 176 can have a height of about 8″ (about 20.3 cm) or less, such as about 4.5″ (about 11.4 cm) or less, about 4″ (about 10.2 cm) or less, about 1″ (about 2.54 cm) or less, etc. The rib 175 or 176 can have a height of about ½″ (about 1.27 cm) or greater, such as about 1″ (about 2.54 cm) or greater, 4″ (about 10.2 cm) or greater, about 4.5″ (about 11.4 cm) or greater, etc. In some embodiments, the rib 175 or 176 can have a height in the range of about 4″ to about 4.5″.

As described herein, the ribs 175, 176 can be formed on the back pan 170 such that the rib 175 or 176 is at least partially disposed between the top surface 191 and the bottom surface 192 of the safing insulation 190. With reference to FIG. 8, in certain aspects, the back pan 170 may include rib 176 disposed at least partially above a first height S which corresponds to about 50% of the height S of the safing insulation 190. In other words, at least a portion of the rib 176 is positioned above a midpoint between the bottom surface 192 and the top surface 191 of the safing insulation 190. Further, the back pan 170 may include the rib 176 disposed at least partially below a second height S2 which corresponds to about 75% of the height S of the safing insulation. In other words, at least a portion of the rib 176 is positioned below a point that is located midway between the aforementioned midpoint and the top surface 191 of the safing insulation 190.

In certain embodiments, and as shown in FIGS. 9-11, the safing 190 can include a relief shape 1002. The relief shape 1002 corresponds to a shape of an interior facing rib 175. Accordingly, the safing 190 may be more accurately positioned within the perimeter void 165 without the rib 175 creating a bulge, such as a bulge on the top surface 191 of the safing 190. Further, in certain embodiments, and as shown in FIG. 9, the safing 190 can include a ramped section 1004. The ramped section 1004 may have a depth into the safing insulation approximately equal to a depth of the rib 175. Accordingly, ease of installing the safing 190 may be improved by ramping up the force required to friction fit the safing 190 into the perimeter void 165 as the safing 190 is increasingly compressed by the rib 175 as the rib 175 travels along the ramped section 1004.

With reference to FIGS. 12 and 13, in certain aspects, the back pan 170 includes at least one of an interior facing rib 175 or an exterior facing rib 176, where the rib 175 or 176 may extend fully or partially across a width of the back pan 170. As seen in FIG. 12, in certain aspects, the back pan 170 includes rib 176 extending fully across the width of the back pan 170. For example, the rib 176 extends through the flange 177 on one or both ends of the back pan 170. As seen in FIG. 13, in certain aspects, the back pan 170 includes rib 175 extending partially across the width of the back pan 170. For example, the rib 175 extends across a majority of the width of the back pan 170, however, there is a distance D from an end of the rib 175 to a widthwise end of the back pan 170 (e.g., a vertical edge of the back pan 170 at an intersection of the interior facing surface 172 and the flange 177). Furthermore, as seen in FIG. 13, one or more ribs can be positioned on the back pan 170 such that the back pan 170 is symmetrical across a central vertical axis Y-Y and/or a central horizontal axis X-X. For example, the distance D may be substantially equal from each end of the rib 175 to a vertical edge of the back pan 170 such that the back pan 170 is symmetrical across axis Y-Y. In such an embodiment, the back pan 170 may have similar resistance to warping across a width of the back pan 170.

As shown in FIG. 12, the rib 176 is triangular-shaped and extends into a depth of the back pan 170. While the rib 176 can extend to any practical depth, in certain embodiments, the rib 176 extends to 50% or less of the depth of the back pan 170. In some embodiments, the rib 176 extends to a depth of 20% to 40% of the thickness of the back pan 170. In certain embodiments, the rib 176 extends to a depth of about 33% of the thickness of the back pan 170. For example, if the back pan 170 is about 7.62 cm thick, the rib 176 would extend about 2.54 cm into the back pan 170. The rib 176 is situated between the first end 173 and the second end 174 of the back pan 170. In the exemplary embodiment shown in FIG. 12., the rib 176 is situated closer to the first end 173 than the second end 174. In FIG. 12, an upper portion of the rib 176 is substantially flush with the interior facing surface 172 of the back pan and slopes (at an angle θ) into the back pan 170 to reach the aforementioned depth (e.g., of about 2.54 cm or ⅓ the thickness of the back pan 170). Here, θ is in the range of about 75 degrees to about 79 degrees, such as about 77 degrees. In this manner, the lower portion of the rib 176 is a substantially flat 2.54 cm “shelf” formed in the back pan 170.

As seen in FIG. 13, in certain aspects, the back pan 170 includes the rib 175 and a second rib 175a, where the ribs 175, 175a are substantially equally spaced from the central horizontal axis X-X that is disposed midway between the first end 173 and the second end 174. In other words, ribs can be formed on the back pan 170 such that the back pan 170 is symmetrical along a horizontal axis. In such an embodiment, the back pan 170 may be installed such that the first end 173 is an upper end of the back pan 170 or such that the second end 174 is an upper end of the back pan 170 without degrading the ability of the back pan 170 to resist warping when exposed to heat, such as heat from a fire.

Referring now to FIGS. 14 and 15, an embodiment of an insulated curtain wall component 200 is illustrated. The insulated curtain wall component 200 may be used to form at least a portion of a curtain wall unit of a unitized curtain wall system. In a unitized curtain wall system, individual curtain wall units are prefabricated in a factory setting and then delivered to a construction site for installation.

As seen in FIG. 14, the insulated curtain wall component 200 includes framing defined by at least first and second vertically disposed and parallel mullions 250, 252 and at least first and second horizontally disposed and parallel transoms, such as an upper horizontally disposed transom 254 and a lower horizontally disposed transom 256. The transoms 254, 256 are separated by a transom distance T_D, which corresponds to the distance between a bottom surface 254a of the first transom 254 and a top surface 256a of the second transom 256, as illustrated in FIG. 15. The mullions 250, 252 and transoms 254, 256 are typically hollow box-shaped members formed of aluminum. As shown in FIG. 15, the insulated curtain wall component 200 may also include a spandrel panel 255 connected to the framing. The spandrel panel 255 provides an exterior fac̨ade and is commonly formed of glass, aluminum, stone, thin sheets of foam material, and the like.

With continued reference to FIGS. 14 and 15, the insulated curtain wall component 200 includes a back pan 270 interfaced with the framing. The back pan 270 can interface with the framing in a variety of ways. For example, the back pan 270 can be interfaced with, or otherwise joined to, the framing by mechanical fasteners (e.g., screws), by welding, or other techniques known to those of skill in the art. The back pan 270 may be formed of a metal or a metal alloy, although other materials that function as a vapor barrier and are otherwise suitable for use in unitized curtain wall system applications may be used. In certain embodiments, the back pan 270 comprises galvanized steel. In certain embodiments, the back pan 270 comprises galvanized steel having a gauge of 16 to 26. In certain embodiments, the back pan 270 comprises galvanized steel having a gauge of 16 to 22.

As seen in FIG. 15, the back pan 270 has an exterior facing surface 271 and an interior facing surface 272. In addition, the back pan 270 has an installed length L_I and a material length. As seen in FIG. 15, the installed length L_I corresponds to the linear length measured from a first end 273 of the back pan 270 to a second end 274 of the back pan 270. The material length corresponds to the length measured along the back pan 270 itself from the first end 273 to the second end 274.

In accordance with the present disclosure, the installed length L_I of the back pan 270 is greater than or equal to the transom distance T_D. Thus, the installed length L_I ensures that the area between the transoms 254, 256 is covered by the back pan 270, as illustrated in FIG. 14. In certain embodiments, the installed length L_I of the back pan 270 is 2 cm to 8 cm greater than the transom distance T_D. In certain embodiments, the installed length L_I of the back pan 270 is 5 cm to 8 cm greater than the transom distance T_D so that the first and second ends 273, 274 of the back pan 270 overlap the transoms 254, 256 by 2.5 cm to 4 cm. Moreover, similar to a back pan 170 having a flange 177 as shown in FIG. 6A, the back pan 270 (e.g., in an embodiment where the back pan 270 includes a flange) can have an exterior installed length approximately equal to the transom distance TD. Thus, the exterior installed length of the back pan 270 ensures that the area between the transoms 254, 256 is covered by the back pan 270. Furthermore, similar to the back pan 170 shown in FIG. 6A, the back pan 270 can have an interior installed length that is less than or equal to the transom distance T_D, thereby creating a gap between the interior facing surface 272 of the back pan 170 and either or both of the transoms 254, 256. Similarly, an interior installed width of the back pan 270 may be less than a distance between mullions 252, thereby creating a gap between the interior facing surface 272 of the back pan 270 and either or both of the mullions 252.

In accordance with the present disclosure, the material length of the back pan 270 is greater than the installed length LI of the back pan 270. Further, the material length of the back pan 270 can be greater than the exterior installed length (e.g., due to a flange and/or a rib on the back pan 270). Furthermore, a portion of the material length of the back pan 270 between the ends 273, 274 (i.e., excluding a flange of the back pan 270), can be greater than the interior installed length (e.g., due to a rib on the back pan 270). In some exemplary embodiments, the material length results from controlled deformation of a flat metal or metal alloy sheet (e.g., a sheet of galvanized steel), such as by stamping, crimping, or corrugating techniques. By having a material length that is greater than the installed length L_I, the strength of the back pan 270 is increased as compared to a back pan having a material length that is equal to the installed length L_I, given the same material composition and thickness. Accordingly, the back pan 270 of the present disclosure has sufficient strength such that it can be utilized in a perimeter fire containment system without having to attach a separate reinforcing member (such as reinforcing members 71, 72 required in the system 10 illustrated in FIG. 1) to support/reinforce a safing insulation that is compression fit between a floor slab and the back pan 270.

In certain embodiments, the back pan 270 has a material length that is about 0.1% to about 100% greater than the installed length L_I. In certain embodiments, the back pan 270 has a material length that is about 0.5% to about 20% greater than the installed length L_I. In certain embodiments, the back pan 270 has a material length that is about 0.75% to about 10% greater than the installed length L_I. In certain embodiments, the back pan 270 has a material length that is about 1% to about 4% greater than the installed length L_I.

As seen well in FIG. 15, in certain aspects, the back pan 270 comprises an interior facing rib 275 configured to abut at least a portion of a safing insulation of a perimeter fire containment system. In certain aspects, the back pan 270 comprises an exterior facing rib 276 that abuts at least a portion of a curtain wall insulation 280 of the insulated curtain wall component 200. In certain aspects, the back pan 270 comprises at least one interior facing rib 275 and at least one exterior facing rib 276. The back pan 270 of the insulated curtain wall component 200 can be formed in a variety of configurations or shapes, including the shapes and configurations previously described with respect to FIGS. 2-13.

In certain embodiments, the back pan 270 includes an intumescent coating (not shown) applied to at least a portion of the interior facing surface 272 of the back pan 270. In certain aspects, an intumescent coating is applied to the entire interior facing surface 272 of the back pan 270. In certain aspects, an intumescent coating is applied to a portion of the interior facing surface 272 of the back pan 270 that, after installation of the insulated curtain wall component 200, is positioned adjacent to a safing insulation of a perimeter fire containment system. Any commercially available intumescent coating material may be used for the intumescent coating that is applied to the interior facing surface 272 of the back pan 270. Examples of suitable intumescent coating material that may be used include FlameOff® fire barrier paint, which is commercially available from FlameOff Coatings, Inc. (Raleigh, North Carolina), and FireGuard® E-84 intumescent coating, which is commercially available from Shield Industries, Inc. (Woodstock, Georgia).

The insulated curtain wall component 200 of the present disclosure also includes a curtain wall insulation 280, as seen in FIG. 15. The curtain wall insulation 280 may be formed of various materials based on a desired failure temperature of the material such as mineral wool. Such curtain wall insulation 280 is commercially available from Thermafiber, Inc. (Joplin, Missouri). The curtain wall insulation 280 may have a thickness of 2.54 cm to 20.32 cm and a density of 64 kg/m³ to 225 kg/m³. The curtain wall insulation 280 is disposed within the framing. Accordingly, the size and shape of the curtain wall insulation 280 will typically depend on the size and shape of the framing into which the curtain wall insulation 280 is being installed. In certain aspects, the curtain wall insulation 280 is mechanically attached to the framing, for example, with insulation hangers (not shown), such as Impasse® insulation hangers available from Thermafiber, Inc. (Joplin, Missouri), or by other conventional means used to mechanically attach curtain wall insulation 280 to framing. In certain aspects, the curtain wall insulation 280 is friction fit within the framing. In certain aspects, the curtain wall insulation 280 is secured to at least a portion of the exterior facing surface 271 of the back pan 270. For example, as seen in FIG. 15, the curtain wall insulation 280 may be secured to at least a portion of the exterior facing surface 271 of the back pan 270 with one or more fasteners 281 (e.g., cup head weld pins).

The terminology as set forth herein is for description of the embodiments only and should not be construed as limiting the disclosure as a whole. All references to singular characteristics or limitations of the present disclosure shall include the corresponding plural characteristic or limitation, and vice versa, unless otherwise specified or clearly implied to the contrary by the context in which the reference is made. Unless otherwise specified, “a,” “an,” “the,” and “at least one” are used interchangeably. Furthermore, as used in the description and the appended claims, the singular forms “a,” “an,” and “the” are inclusive of their plural forms, unless the context clearly indicates otherwise.

To the extent that the term “includes” or “including” is used in the description or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed (e.g., A or B) it is intended to mean “A or B or both.” When the applicants intend to indicate “only A or B but not both” then the term “only A or B but not both” will be employed. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. Furthermore, when the phrase “one or more of A and B” is employed it is intended to mean “only A, only B, or both A and B.” Similarly, when the phrases “at least one of A, B, and C” or “at least one of A, B, C, and combinations thereof” are employed, they are intended to mean “only A, only B, only C, or any combination of A, B, and C” (e.g., A and B; B and C; A and C; A, B, and C).

The system of the present disclosure can comprise, consist of, or consist essentially of the essential elements of the disclosure as described herein, as well as any additional or optional element or feature described herein, or which is otherwise useful in curtain wall insulation applications.

All ranges and parameters, including but not limited to percentages, parts, and ratios, disclosed herein are understood to encompass any and all sub-ranges assumed and subsumed therein, and every number between the endpoints. For example, a stated range of “1 to 10” should be considered to include any and all sub-ranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 1 to 6.1, or 2.3 to 9.4), and to each integer (1, 2, 3, 4, 5, 6, 7, 8, 9, and 10) contained within the range.

Unless otherwise indicated herein, all sub-embodiments and optional embodiments are respective sub-embodiments and optional embodiments to all embodiments described herein. While the present disclosure has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the present disclosure, in its broader aspects, is not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general disclosure herein.

The scope of the general inventive concepts presented herein are not intended to be limited to the particular exemplary embodiments shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the devices and systems disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and/or claimed herein, and any equivalents thereof.