VERTICALLY ADJUSTABLE CURTAIN WALL BRACKET

Description

BACKGROUND

A curtain wall is an exterior covering of a building in which the outer walls are non-structural. Rather, curtain walls primarily serve to protect the interior of the building from environmental elements. Because they carry no structural load beyond its own dead weight, curtain walls can be made of lightweight materials. Following installation, the current wall transfers lateral wind loads to the main building structure through connections at floors or columns of the building.

Curtain wall architecture typically includes a plurality of vertical structural members or “mullions” secured to a plurality of horizontal structural members or “stiles”, and the interconnected vertical and horizontal structural members are adapted to frame and hold glazing panels, such as panes of window glass, polycarbonates, or other clear, translucent, tinted, or opaque panels. To install an assembled curtain wall panel, an anchor or bracket is first fastened to an edge of a building floor or column. Such brackets can be attached to the top or front face of a floor substrate, for instance. The assembled curtain wall panel is then secured to the bracket and thereby “hung” from the building substrate.

Building movement is a growing issue within curtain walls. As building structures become more complex, and with an increased desire to reduce material usage, curtain walls panels are more prone to movement during and after installation. Once a curtain wall facade is installed, for example, the floor perimeter can “sag” under the weight, and such deflection is often not evenly distributed throughout the building. Consequently, mullions in a particular curtain wall panel can have different vertical positions relative to level, and this can potentially result in “racking” where the glass or infill of the curtain wall panel contacts the metal frame.

External facade systems need to be able to accommodate movement within its frames, yet as movements become greater, some façade systems become less feasible. What is needed is a system that enables vertical adjustment of the mullions in installed curtain wall panels, thereby eliminating the twisting or “racking” of curtain wall panels.

SUMMARY OF THE DISCLOSURE

Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter.

Embodiments disclosed herein include a curtain wall window system for a building that includes a horizontally-extending substrate forming part of the building, a curtain wall panel mountable to the substrate and including a mullion, and a curtain wall bracket assembly that operatively couples the curtain wall panel to the substrate. The curtain wall bracket assembly may include a backplate securable to the substrate, a bracket in sliding engagement with the backplate, and an adjustment mechanism that operatively couples the bracket to the backplate, wherein manually actuating the adjustment mechanism causes the bracket to move vertically relative to the backplate, and wherein the mullion is attachable to the bracket such that vertical movement of the bracket correspondingly moves the mullion. In a further embodiment, the backplate provides an adjustment aperture and the bracket provides a lateral projection defining a projection aperture vertically alignable with the adjustment aperture, the adjustment mechanism including a threaded bolt extendable through the adjustment aperture and the projection aperture, a threaded nut threadable to an end of the threaded bolt such that the lateral projection interposes the adjustment aperture and the threaded nut, wherein rotating the threaded bolt moves the threaded nut along the threaded bolt and thereby moves the bracket vertically. In another further embodiment, the backplate comprises a planar body providing opposing front and back faces, the back face being arranged against the substrate, a pair of backplate legs extending from the front face and laterally spaced from each other such that a vertical slot is defined therebetween to receive the bracket, and a back wall extending laterally between the pair of backplate legs, wherein the adjustment aperture is provided on the back wall and comprises a vertical aperture extending vertically along at least a portion of a vertical height of the back wall. In another further embodiment, the vertical slot is a first vertical slot and a first engagement feature is provided on each backplate leg, and wherein the bracket comprises a U-shaped body including an end wall and a pair of bracket legs extending from the end wall, the pair of bracket legs being laterally offset from each other such that a second vertical slot is defined therebetween to receive the mullion, and a second engagement feature provided on each bracket leg and configured to slidably engage the first engagement feature of an adjacent backplate leg, and there-by slidably coupling the bracket to the backplate. In another further embodiment, when the threaded nut is threaded to the threaded bolt, a flat surface of the threaded nut bears against a back-side of the end wall and thereby prevents the threaded nut from rotating as the threaded bolt rotates. In another further embodiment, each bracket leg defines an aperture alignable with corresponding apertures defined in the mullion and sized to receive one or more mechanical fasteners used to secure the mullion to the bracket. In another further embodiment, the aperture defined in each bracket leg is horizontally elongated to allow horizontal adjustment of the mullion relative to the curtain wall bracket assembly. In another further embodiment, the curtain wall bracket assembly further includes a locking mechanism attachable to the backplate and engageable with a head of the threaded bolt to prevent the threaded bolt from rotating.

Embodiments disclosed herein may further include a curtain wall bracket assembly that includes a backplate securable to a substrate of a building, a bracket in sliding engagement with the backplate, and an adjustment mechanism that operatively couples the bracket to the back-plate, wherein manually actuating the adjustment mechanism causes the bracket to move vertically relative to the backplate. In a further embodiment, the backplate provides an adjustment aperture and the bracket provides a lateral projection defining a projection aperture vertically alignable with the adjustment aperture, the adjustment mechanism including a threaded bolt extendable through the adjustment aperture and the projection aperture, a threaded nut threadable to an end of the threaded bolt such that the lateral projection interposes the adjustment aperture and the threaded nut, wherein rotating the threaded bolt moves the threaded nut along the threaded bolt and thereby moves the bracket vertically. In another further embodiment, wherein the backplate comprises a planar body providing opposing front and back faces, the back face being arranged against the substrate, a pair of backplate legs extending from the front face and laterally spaced from each other such that a vertical slot is defined therebetween to receive the bracket, and a back wall extending laterally between the pair of backplate legs, wherein the adjustment aperture is provided on the back wall and comprises a vertical aperture extending vertically along at least a portion of a vertical height of the back wall. In another further embodiment, the back wall defines a channel through which the lateral projection traverses as the bracket is moved vertically relative to the backplate. In another further embodiment, wherein the vertical slot is a first vertical slot and a first engagement feature is provided on each backplate leg, and wherein the bracket comprises a U-shaped body including an end wall and a pair of bracket legs extending from the end wall, the pair of bracket legs being laterally offset from each other such that a second vertical slot is defined therebetween to receive the mullion, and a second engagement feature provided on each bracket leg and configured to slidably engage the first engagement feature of an adjacent backplate leg, and thereby slidably coupling the bracket to the backplate. In another further embodiment, when the threaded nut is threaded to the threaded bolt, a flat surface of the threaded nut bears against a backside of the end wall and thereby prevents the threaded nut from rotating as the threaded bolt rotates. In another further embodiment, the first and second engagement features comprise a dovetail engagement. In another further embodiment, the end wall and the back wall are placed in sliding engagement when the bracket is received within the first vertical slot. In another further embodiment, the curtain wall bracket assembly further includes a locking mechanism attachable to the backplate and engageable with a head of the threaded bolt to prevent the threaded bolt from rotating. In another further embodiment, the locking mechanism includes an elongate bar having opposing first and second ends, and a locking profile provided at an intermediate location between the first and second ends and configured to engage one or more flat surfaces of the head.

Embodiments disclosed herein may further include a method of installing a curtain wall panel for a building, the method may include securing a backplate of a curtain wall bracket assembly to a horizontally-extending substrate forming part of the building, placing a bracket of the curtain wall bracket assembly in sliding engagement with the backplate, attaching a mullion of the curtain wall panel to the bracket, operatively coupling the bracket to the backplate with an adjustment mechanism of the curtain wall bracket assembly, and manually actuating the adjustment mechanism and thereby causing the bracket and the mullion to move vertically relative to the backplate and the substrate. In a further embodiments, the backplate provides an adjustment aperture and the bracket provides a lateral projection defining a projection aperture vertically alignable with the adjustment aperture, the adjustment mechanism including a threaded bolt and a threaded nut, and wherein operatively coupling the bracket to the backplate comprises extending the threaded bolt through the adjustment aperture and the projection, threading the threaded nut to an end of the threaded bolt such that the lateral projection interposes the threaded nut and the adjustment aperture, and rotating the threaded bolt and thereby moving the threaded nut along the threaded bolt and correspondingly moving the bracket and the mullion vertically.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.

FIG. 1 is an exploded, perspective view of a prior art curtain wall panel.

FIG. 2 is an isometric view of a plurality of curtain wall panels assembled to form a portion of a curtain wall system.

FIG. 3 is an isometric side view of an example curtain wall bracket assembly, according to one or more embodiments of the present disclosure.

FIGS. 4A-4C are isometric views of various component parts of the curtain wall bracket assembly of FIG. 3, according to one or more embodiments.

FIGS. 5A and 5B are isometric top and bottom views of the curtain wall bracket assembly of FIG. 3 in another progressive step of assembly, according to one or more embodiments.

FIGS. 6A and 6B are enlarged isometric views of the curtain wall bracket assembly being operatively coupled to a mullion, according to one or more embodiments.

FIGS. 7A and 7B are isometric and partial cross-sectional side views, respectively, of the curtain wall bracket assembly being manually adjusted to alter the vertical position of the mullion, according to one or more embodiments.

FIGS. 8A and 8B are enlarged, isometric views of the curtain wall bracket assembly, according to one or more additional embodiments.

FIGS. 9A-9C depict alternative applications of the curtain wall bracket assembly, according to additional embodiments.

FIG. 10 is an isometric view of an alternative embodiment of the curtain wall bracket assembly.

DETAILED DESCRIPTION

The present disclosure is related to curtail wall assemblies and, more specifically, to a curtain wall bracket assembly that can be manually adjusted to alter the vertical position of interconnected curtain wall panels.

Disclosed herein is a curtain wall window system for a building. The curtail wall window system can include a horizontally-extending substrate forming part of the building, a curtain wall panel mountable to the substrate and including a mullion, and a curtain wall bracket assembly that operatively couples the curtain wall panel to the substrate. The curtain wall bracket assembly may include a backplate securable to the substrate, a bracket in sliding engagement with the backplate, and an adjustment mechanism that operatively couples the bracket to the backplate. Manually actuating the adjustment mechanism can cause the bracket to move vertically relative to the backplate, and the mullion is attachable to the bracket such that vertical movement of the bracket correspondingly moves the mullion. Accordingly, the curtain wall bracket assembly may allow an installer to adjust the vertical position of the curtain wall panel at the mullion during and after installation, thereby eliminating the twisting or “racking” of curtain wall panels. The curtain wall bracket assembly may also be used to simply adjust the vertical height of entire curtain wall panels, as needed.

FIG. 1 is an isometric exploded view of a prior art curtain wall panel 100, which may form part of a curtain wall system for a residential or commercial building. More specifically, FIG. 1 depicts the chassis subassembly for a curtain wall panel. The chassis subassembly may be made for installation in a large commercial building, such as a skyscraper, but could alternatively be applied to smaller commercial or residential buildings. The principles of the present disclosure, however, are equally applicable to all types of fenestration systems.

As illustrated, the curtain wall panel 100 includes vertical structural members 102a and 102b, and horizontal structural members 104a, 104b, and 104c. The vertical and horizontal structural members 102a,b and 104a-c may be extruded from an aluminum alloy, which is strong, lightweight and corrosion-resistant, but may alternatively be formed of other materials, such as other metals, metal alloys, or a composite material. The structural members 102a,b, 104a-c may be adapted to cooperatively frame and hold a panel, such as a pane of window glass, polycarbonate, or another clear, translucent, tinted, or opaque panel. In at least one embodiment, the vertical and horizontal structural members 102a,b, 104a-c may be adapted to frame and hold a plurality of glazing panels (e.g., the glazing panels 208a-208j of FIG. 2).

The vertical and horizontal structural members 102a,b, 104a-c are joined using one or more fasteners 106 to secure the glazing panel(s) and thereby form the curtain wall panel 100. The fasteners 106 may include screws, rivets, welds, other known mechanical fastening means, or any combination thereof.

FIG. 2 is an isometric view of a plurality of curtain wall panels 100 assembled to form a portion of a curtain wall window system 202. The curtain wall window system 202 may be secured to a building structure at one or more substrates 204 that form part of the building structure. As illustrated, for example, the substrate 204 may comprise a building floor or beam that extends substantially horizontal. The curtain wall panels 100 may be coupled to one another and secured to one or more substrates 204 at one or more brackets mounted to the substrate 204 at or near its outer (exterior) edge. In some applications, for example, one or more first brackets 206a may be fastened to the top of the substrate 204 at or near the edge of the substrate 204. In other applications, one or more second brackets 206b may be fastened to a front face of the substrate 204a. The curtain wall panels 100 may be secured to the corresponding bracket 206a,b and thereby “hung” from the building substrate 204.

The curtain wall panels 100 have a plurality of glazing panels 208a-208j (e.g., glass), alternately referred to as “glazing units,” installed therein between the vertical and horizontal structural members (102b and 104a indicated). In modern construction, the glazing panels 208a-j are typically double or triple glazed with air, an inert gas, and/or a plastic film(s) between adjacent panels to control transmission of thermal energy by radiation and convection between the interior of the building and the exterior environment. In some applications, the glazing panels 208a-j may be secured to the corresponding curtain wall panels 100 by way of a silicone adhesive/sealant or structural tape. In other embodiments, however, one or more cover elements or “covers” 210 may be utilized to provide an architectural finishing detail between adjacent glazing panels 208a-j and/or provide a mechanism for supporting the glazing panels 208a-j in place on the window system 202.

Building movement can be a concern for the curtain wall window system 202. The curtain wall panels 100 can be prone to movement during and after installation, and once the curtain wall window system 202 is installed, portions of the substrate 204 may “sag” under the weight. Such deflection of the substrate 204 may not be evenly distributed and, as a result, horizontal structural members 102a,b (FIG. 1) of a given curtain wall panel 100 may have different vertical positions relative to each other and relative to level. As noted above, this can potentially result in “racking” where the glazing panels 208a-j contact portions of the curtain wall panel 100, potentially resulting in cracking or breaking of the glazing panel 208a-j.

According to embodiments of the present disclosure, a vertically adjustable curtain wall bracket assembly may be used to operatively coupled curtain wall panels to an adjacent substrate (e.g., a building floor, a beam, etc.) of a building. The curtain wall bracket assemblies described herein allow an installer to adjust the vertical position of each horizontal structural member 102a,b (FIG. 1) during and after installation, thereby eliminating the twisting or “racking” of curtain wall panels. The curtain wall bracket assembly may also be used to simply adjust the vertical height of entire curtain wall panels, as needed.

FIG. 3 is an isometric side view of an example curtain wall bracket assembly 300, according to one or more embodiments of the present disclosure. As illustrated, the curtain wall bracket assembly 300 (hereafter “the assembly 300”) may be secured to a substrate 302 of a building and extend laterally outward therefrom. In some embodiments, the substrate 302 may comprise a building floor made of reinforced concrete. In other embodiments, however, and as mentioned below, the substrate 302 may alternatively comprise a horizontally-extending universal beam (UB), such as an I-beam or a rectangular hollow section beam.

In some embodiments, as illustrated, the assembly 300 may be secured to a front face 304 of the substrate 302. While not shown, the assembly 300 may be secured to the front face 304 using one or more mechanical fasteners (e.g., bolts, anchors, cast-in channels, etc.) or the like. In other embodiments, however, the assembly 300 may be mounted to an anchor (not shown) that is secured to a top face 306 of the substrate 302.

As illustrated, the assembly 300 may include a variety of component parts including an anchor or “backplate” 308 and an adjustable bracket 310. The backplate 308 may be configured to be secured, fastened, and otherwise coupled to the substrate 302, thereby providing an anchor point for the assembly 300 to the substrate 302. The bracket 310 may be movably or adjustably coupled to the backplate 308, and further configured to be coupled to a structural member of a curtain wall panel, such as a vertical member or “mullion” 312. The mullion 312 may be the same as or similar to the vertical structural members 102a,b of FIG. 1. Consequently, the assembly 300 may be used to help mount the curtain wall panels 100 (FIGS. 1 and 2) to a building.

As described in more detail below, the assembly 300 may be vertically adjustable by an installer, either during or after installation. More specifically, the bracket 310 may be vertically adjusted relative to the backplate 308, thereby enabling the installer to adjust the vertical position of the mullion 312 relative to the substrate 302 (and also relative to an opposing mullion in the same curtain wall panel). This helps the installer prevent or avoid twisting or “racking” of the corresponding curtain wall panel, but also allows the installer to merely adjust the vertical height of the curtain wall panel, as needed.

FIGS. 4A-4C are isometric views of various component parts of the assembly 300 of FIG. 3, according to one or more embodiments. More specifically, FIG. 4A is an isometric view of the backplate 308, FIG. 4B is an isometric view of the bracket 310, and FIG. 4C is an isometric view of the bracket 310 slidably received within a portion of the backplate 308 and otherwise adjustably coupled thereto. The backplate 308 and the bracket 310 may be made of a variety of rigid materials including, but not limited to, iron, steel, aluminum, a composite material, a hardened plastic, or any combination thereof.

Referring first to FIG. 4A, the backplate 308 provides a planar body 402 and a pair of backplate legs 404 that extend laterally from the planar body 402. The planar body 402 may exhibit a substantially polygonal shape, such as rectangular or square. In other embodiments, however, the planar body 402 may exhibit other shapes, such as circular or oval. The planar body 402 provides opposing front and back faces 406a and 406b, and the backplate legs 404 extend perpendicularly from the front face 406b. The back face 406b may be configured to be arranged against the front face 304 (FIG. 3) of the substrate 302 (FIG. 3).

The backplate legs 404 may extend parallel to one another, and each backplate leg 404 provides opposing first and second ends 408a and 408b. The first end 408a of each backplate leg 404 is coupled to and otherwise located at the front face 406a of the planar body 402. A first engagement feature 410a may be provided at the second end 408b of each backplate leg 404. The first engagement features 410a may be configured and otherwise designed to engage and interact with corresponding engagement features of the bracket 310 (FIG. 4B), thereby slidably coupling the bracket 310 to the backplate 308.

The backplate legs 404 are laterally offset from each other such that a vertical slot 412 is defined between the backplate legs 404. The vertical slot 412 may be sized and otherwise configured to slidably receive a portion of the bracket 310 (FIG. 4B). The backplate 308 may further include or define a back wall 414 extending laterally between the backplate legs 404, and thereby helping to define the slot 412. In some embodiments, as illustrated, the back wall 414 may be arranged (provided) at a location between the first and second ends 408a,b, and otherwise offset from the front face 406b of the planar body 402 (e.g., the front face 406B) such that a gap 416 is defined therebetween.

The backplate 308 may further provide or otherwise define an adjustment aperture 418. As illustrated, the adjustment aperture 418 may be provided or otherwise defined by the back wall 414, and protrudes into the gap 416. The adjustment aperture 418 may comprise a vertical aperture that extends vertically along at least a portion of the vertical height of the back wall 414. The adjustment aperture 418 may be configured to receive an adjustment mechanism that is manually manipulatable (rotatable) to adjust the vertical height of the bracket 310 (FIG. 4B) relative to the backplate 308.

Referring now to FIG. 4B, the bracket 310 provides a generally U-shaped body 420 including an end wall 422 and a pair of bracket legs 424. The bracket legs extend parallel to each other and perpendicularly from the end wall 422, and are laterally offset such that a vertical slot 426 is defined therebetween. The vertical slot 426 may be sized and otherwise configured to receive and seat a structural component of a curtain wall panel, such as the mullion 312 (FIG. 3). Each bracket leg 424 may define an aperture 428 alignable with corresponding apertures (not shown) defined in the mullion 312 and sized to receive one or more mechanical fasteners used to secure the mullion 312 to the bracket 310, and thereby securing the mullion 312 to the assembly 300. In some embodiments, as illustrated, the apertures 428 may be horizontally elongated, which may prove advantageous in allowing horizontal (e.g., in-and-out) adjustment of the mullion 312 during initial installation. In other embodiments, however, the apertures 428 may not be elongated, but may instead comprise circular apertures, commonly referred to as “dead fix” holes.

In some embodiments, as illustrated, the laterally outward surfaces of each bracket leg 424 (e.g., the surfaces outside of the vertical slot 426) may be serrated and otherwise define a serrated or grooved surface. As described in more detail below, the serrated surfaces may be matable or otherwise engageable with a correspondingly serrated washer plate to help control horizontal (e.g., in-and-out) adjustment and tolerance of the mullion 312 during initial installation.

Each bracket leg 424 may further include or provide a corresponding second engagement feature 410b, provided at a point between the ends of the bracket legs 424. The second engagement features 410b may be configured to engage and interact with the first engagement features 410a (FIG. 4A), thereby slidably coupling the bracket 310 to the backplate 308.

Referring now to FIG. 4C, with continued reference to FIGS. 4A-4B, illustrated is a first step in assembling the assembly 300. More specifically, the bracket 310 is shown as being slidably received within the vertical slot 412 of the backplate 308. Receiving the bracket 310 within the vertical slot 412 allows the first and second engagement features 410a,b to engage and slidably interact with each other, which allows the bracket 310 to move vertically, as indicated by the arrow A. As discussed in more detail below, this may prove advantageous in allowing an installer to adjust the vertical position of the mullion 312 (FIG. 3), as needed.

In some embodiments, as illustrated, the first and second engagement features 410a,b may comprise a dovetail engagement, in which each engagement feature 410a,b provides opposing angled surfaces configured to slidably engage against each other. The dovetail engagement may prove advantageous for a variety of reasons. For example, the dovetail engagement allows the bracket 310 to self-align with the backplate 308 upon being received within the vertical slot 412. Consequently, when the curtain wall panel is subjected to suction load, the bracket 310 will tend to be pulled centrally and evenly on the backplate 308, which ensures that the load is shared across both backplate legs 404. Moreover, the dovetail engagement interlocks the bracket 310 to the backplate 308, thereby preventing the backplate legs 404 from opening up laterally and potentially disengaging from the bracket 310.

In some embodiments, slidably mating the bracket 310 with the backplate 308 may result in the creation of at least three contact surfaces between the two component parts. More specifically, the bracket 310 may slidably mate with the backplate 308 at first and second contact surfaces generated by the sliding interaction between the first and second engagement features 410a,b. Moreover, in some embodiments, a third contact surface may be generated at the sliding engagement between the end wall 422 of the bracket 310 and the back wall 414 of the backplate 308. These three contact surfaces help to prevent movement in X and Y directions, therefore, tolerance control can be focused on critical contact points.

FIGS. 5A and 5B are isometric top and bottom views of the assembly 300 in another progressive step of assembly, according to one or more embodiments. More specifically, as illustrated, the bracket 310 is slidably received by the backplate 308, as generally described above. To facilitate vertical adjustment of the bracket 310 relative to the backplate 308, the assembly 300 may further include an adjustment mechanism 502 that operatively couples the bracket 310 to the backplate 308. When building a curtain wall system, an installer may be able to access and manually actuate (e.g., rotate) the adjustment mechanism 502 to thereby adjust the vertical position of the bracket 310, which correspondingly adjusts the vertical position of the mullion 312 (FIG. 3) operatively coupled thereto.

In some embodiments, as illustrated, the adjustment mechanism 502 includes a threaded bolt 504 and a threaded nut 506 configured and otherwise sized to be threaded to the end of the threaded bolt 504. The threaded bolt 504 may provide a head 505 (e.g., a hexagonal shaped head) and a threaded shaft that extends from the head 505 and is sized to extend into and through the adjustment aperture 418 (FIG. 4A) such that the distal end of the threaded bolt 504 extends out the bottom of the adjustment aperture 418.

Referring to FIG. 5B, the bracket 310 may include or otherwise define a lateral projection 508 extending from a backside 509 of the end wall 422 and, in some embodiments, the back wall 414 of the bracket 310 may define a channel 510 through which the lateral projection 508 can extend. The channel 510 may be sized such that lateral projection 508 may be able to vertically traverse the channel 510 as the bracket 310 is adjusted vertically relative to the backplate 308. Moreover, the lateral projection 508 may define a projection aperture 512 (shown in dashed lines) through which the threaded bolt 504 can extend after protruding through the bottom end of the adjustment aperture 418 (FIG. 4A). Accordingly, the projection aperture 512 and the adjustment aperture may be vertically alignable. The bracket 310 is operatively (and adjustably) coupled to the backplate 308 by extending the threaded bolt 504 through the adjustment aperture 418 and the projection aperture 512 in the lateral projection 508 and then threading the threaded nut 506 onto the bottom end of the threaded bolt 504.

Referring to both FIGS. 5A and 5B, because of the threaded engagement between the threaded bolt 504 and the threaded nut 506, and since the lateral projection 508 interposes the threaded nut 506 and the adjustment aperture 418, rotating the threaded bolt 504 will correspondingly cause the bracket 310 to move vertically A (FIG. 5A) relative to the backplate 308. The threaded nut 506 may exhibit a generally polygonal shape that provides a plurality of flat surfaces. In the illustrated example, for instance, the threaded nut 506 exhibits a hexagonal shape having six flat surfaces. When the threaded nut 506 is received on the end of the threaded bolt 504, one of the flat surfaces will bear against the backside 509 of the end wall 422, thereby preventing the threaded nut 506 from rotating as the threaded bolt 504 rotates. Rather, this will cause the threaded nut 506 to advance along the axial length of the threaded bolt 504, and thereby simultaneously move the bracket 310 vertically A. As will be appreciated, the bracket 310 can be moved (adjusted) vertically A in either direction (e.g., up or down) depending on the rotational direction of the threaded bolt 504.

FIGS. 6A and 6B are enlarged isometric views of the assembly 300 operatively coupled to the mullion 312, according to one or more embodiments. More specifically, once the assembly 300 is assembled and secured to the substrate 302, as generally described above, the mullion 312 may be received within the vertical slot 426 defined between the bracket legs 424 of the bracket 310. The mullion 312 may define an aperture 602 alignable with the apertures 428 defined in the bracket legs 424. In some embodiments, the aperture 602 may extend all the way through the mullion 312 (e.g., between opposing lateral sides).

Once the aperture 602 is aligned with the apertures 420 defined in the bracket 310, a nut and bolt assembly 604 (FIG. 6B) may be used to secure the mullion 312 to the assembly 300. More specifically, the nut and bolt assembly 604 may include a threaded bolt 606 extendable through the aligned apertures 420, 602, and a threaded nut 608 sized to be threaded onto the end of the threaded bolt 606. Tightening the threaded nut 608 will secure the mullion 312 to the bracket 310, which effectively secures the mullion 312 to the substrate 302.

In some embodiments, as illustrated, the assembly 300 may further include a washer plate 610 that interposes the threaded nut 608 and the laterally outward surface 612 of the corresponding bracket leg 424. On the opposing (non-visible side) of the mullion 312, a second washer plate 610 (not visible) may interpose the head of the threaded bolt 606 and the side wall of the mullion 312. An inner surface 614 of the washer plate 610 may be serrated and otherwise define a serrated or grooved surface configured to engage and mate with the opposing serrated surface of the laterally outward surface 612 of the bracket leg 424. In conjunction with the elongated shape of the apertures 428 defined in the bracket legs 424, mated engagement between the opposing serrated (grooved) surfaces of the washer plate 610 and the outward surface 612 of the bracket legs 424 allows the mullion 312 to be adjusted horizontally; e.g., inward or outward relative to the substrate 302. More specifically, the nut and bolt assembly 604 may be loosened to allow the mullion 312 to be horizontally adjusted. Once the proper horizontal (lateral) position is achieved, the mullion 312 can be secured in place by tightening the nut and bolt assembly 604, which drives the washer plate 610 into engagement with the serrated surface of the laterally outward surface 612, thereby preventing the mullion 312 from horizontal in or out movement.

FIGS. 7A and 7B are isometric and partial cross-sectional side views, respectively, of the assembly 300 being manually adjusted to alter the vertical position of the mullion 312, according to one or more embodiments. More specifically, once the assembly 300 is properly secured to the substrate 302, and the mullion 312 is properly secured to the assembly 300, as generally described above, an installer may manually actuate the adjustment mechanism 502 and thereby adjust the vertical position of the mullion 312. In particular, the installer may access and rotate the threaded bolt 504 in a particular angular direction, as indicated by the arrow B. As the threaded bolt 504 is rotated, the threaded nut 506 will advance vertically along the length of the threaded bolt 504. Since the lateral projection 508 interposes the threaded nut 506 and the adjustment aperture 418, as the threaded nut 506 advances along the threaded bolt 504, the bracket 310 is simultaneously moved in the vertical direction A, which correspondingly moving the mullion 312 in the same vertical direction A.

FIGS. 8A and 8B are enlarged, isometric views of the assembly 300, according to one or more additional embodiments. In some embodiments, the assembly 300 may further include a locking mechanism 802 configured to prevent the adjustment mechanism 502 from reversing and otherwise working loose throughout the lifespan of the building. More specifically, as illustrated, the locking mechanism 802 may include a generally flat and elongate plate or bar 804 having opposing first and second ends 806a and 806b. The bar 804 may be made of a variety of rigid materials including, but not limited to, aluminum, steel, iron, a composite material, a rigid polymer, or any combination thereof.

As illustrated, the bar 804 may provide or otherwise define a locking profile 808 at an intermediate location between the first and second ends 806a,b. The locking profile 808 may be configured to mate or engage with one or more flat surfaces of the head 505 of the threaded bolt 504. Engaging the locking profile 808 against the head 505 will prevent the threaded bolt 504 from rotating, and thereby inadvertently back threading, which would alter the vertical position of the bracket 310 and the mullion 312.

The locking mechanism 802 may be secured to the assembly 300 using one or more mechanical fasteners 810 (two shown). The mechanical fasteners 810 may be extended through corresponding apertures 812 (FIG. 8A) defined in the bar 804 and into corresponding threaded screwports defined in the backplate 308.

FIGS. 9A-9C depict alternative applications of the assembly 300, according to additional embodiments. In FIGS. 9A and 9B, the assembly 300 is mounted to various types of structural beams. In FIG. 9A, the assembly 300 is mounted to an I-beam 902 and, in particular, operatively coupled to the web 904 of the I-beam 902. As illustrated, one or more mechanical fasteners 906 (one shown) may be used to mount the assembly 300 to the I-beam 902. In FIG. 9B, the assembly 300 is mounted to a rectangular hollow section beam 908 and, more particularly, to the front face 910 of the rectangular hollow section beam 908. While two types of structural beams are shown in FIGS. 9A-9B, these are only examples, and the principles of the present disclosure may be implemented with other types of structural beams, without departing from the scope of the disclosure.

In FIG. 9C, the assembly 300 is operatively coupled to the top face 306 of the substrate 302. More specifically, an angle anchor 912 may be secured to the top face 306 with one or more mechanical fasteners 914, and may include a horizontal portion 916 and a vertical portion 918 that extends substantially perpendicular from the horizontal portion 916. As illustrated, the assembly 300 may be secured to the vertical portion 918 of the angle anchor 912 using one or more mechanical fasteners 906 (one shown). It is noted that the angle anchor 912 is only one example of anchors that may be used in conjunction with the principles of the present disclosure, and other anchor configurations are equally applicable.

FIG. 10 is an isometric view of an alternative embodiment of the assembly 300. In the illustrated embodiment, the design of the backplate 308 has been changed to alter the way that the adjustment mechanism 502 operates. More specifically, as illustrated, the backplate 308 may provide or otherwise define a locking mechanism 1002 configured to receive the head 505 of the threaded bolt 504. Once the head 505 is received at the locking mechanism 1002, the threaded bolt 504 will be unable to rotate. Rather, the vertical position of the bracket 310 may be adjusted by rotating the threaded nut 506 at the opposing end of the threaded bolt 504. This may prove advantageous in applications where the assembly 300 is only accessible from its bottom or underside. In some applications, the threaded nut 506 may be prevented from back threading by using a second threaded nut 1004 (shown in dashed lines) tightened against the threaded nut 506.

In some embodiments, as illustrated, a thickness, depth, or length 1006 of the lateral projection 508 may also be increased to correspondingly increase the strength or robustness of the bracket 310. The lateral projection 508 is shown in FIG. 10 with a length 1006 that is much greater than the thickness, depth, or length of the lateral projection 508 depicted in FIGS. 5B and 7B.

Moreover, it is noted that the thickness, depth, length, etc. of other features or components of the assembly 300 may also be increased to thereby increase the robustness of the assembly 300 as a whole. Depending on the structural requirements, for example, the bracket 310 may be made taller and/or thicker in some areas to facilitate larger loads if needed.

Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

As used herein, the phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase “at least one of” allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.

The use of directional terms such as above, below, upper, lower, upward, downward, left, right and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure.