Curtainwall anchor systems and methods

Abstract

An anchoring system configured for anchoring a curtainwall unit of a unitized curtainwall system to a floor slab of a building structure may include an anchor base structure, a slide structure, a hook structure. The anchor base structure may be configured to be attached to the floor slab. The slide structure may be configured to be attached to the curtainwall unit, and the slide structure may include a slide feature with a vertically-oriented length with respect to the curtainwall unit. The hook structure may be configured to be hooked to the anchor base structure. The hook structure may include a slide-receiving feature. The slide-receiving feature and the slide feature of the slide structure may have complementary shapes configured to enable the slide-receiving feature of the hook structure to be slid over the slide feature of the slide structure along the vertically-oriented length of the slide feature.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This patent application claims the benefit of U.S. Provisional Patent Application No. 63 / 775,841, filed Mar. 21, 2025, entitled “CURTAINWALL ANCHOR SYSTEMS AND METHODS”, which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0002] This document relates generally to building construction, and more particularly, but not by way of limitation, to systems and methods for anchoring curtainwalls to a building.BACKGROUND

[0003] Unitized curtainwall is an exterior cladding product for buildings that may be prefabricated and preassembled before shipping to the project site. Advantages may include improved quality as the product may be preassembled in a clean and dry environment, reduced costs as the cost of factory labor is usually significantly less than field labor, and improved scheduling as the curtainwall product can be preassembled before installation, resulting in reduced on-site installation time.

[0004] The primary building structure may have a one-inch to two-inch tolerance or more relative to theoretical positioning. In comparison, the curtainwall system may have an ⅛-inch to 1 / 16-inch tolerance. In order to accommodate these variations, curtainwall systems may be designed to use adjustable anchorage components. Additionally, curtainwall systems may be designed with movable joints to accommodate relative movement between the building structures and curtainwall units. By way of examples and not limitation, such movement may be attributable to machine vibrations, thermal expansion and contraction, wind sway, seismic events, settling of the primary structural system, and floor deflection caused by human traffic, office furniture, or machine traffic. Curtainwall units may be anchored by fixing a top portion of a curtain wall unit to a floor slab, while a bottom portion of the curtainwall unit hangs below that floor slab and mates with another curtainwall unit at a stack joint. The hanging bottom portion of the curtainwall unit has limited freedom of motion at the stack joint to thereby accommodate motion of the building's primary structural system caused by wind, thermal expansion, traffic, and the like. The fixed anchoring of the top portion of the curtainwall unit to the floor slab supports the vertical gravity load and horizontal lateral (wind and seismic) load of the curtain wall and causes the attached curtainwall unit to ride with that floor slab.SUMMARY

[0005] This document discusses, among other things, unitized curtainwall systems, and more particularly systems and methods for anchoring curtainwalls to a building. A benefit of the anchoring system design may include, but is not necessarily limited to, separation of the load paths for wind loads and dead loads, allowing for independent sizing based on project conditions. The dead load, or gravitational force from the weight of the curtainwall panel, may be supported by the threaded fastener (e.g., set screw) within the anchor slide. This threaded fastener resists forces along its threads and is supported by the top of the anchor hook, which slides into the anchor slide. The anchor system may be designed so that the threads of the fastener engage threads within the anchor slide or engage threads within an aperture of a plate attached to the anchor slide. The hook is supported by the anchor base plate. The wind load, or forces perpendicular to the face of the curtainwall panel, is supported through the anchor slide and hook. The outside arms of the hook wrap around the slide profile to resist wind forces. The system is designed to resist forces parallel to the face of the slab, such as seismic or racking forces. A fastener passes through the center of the anchor hook and into the base plate, allowing a single fastener to absorb forces from both directions.

[0006] An example (e.g. “Example 1”) of an anchoring system configured for use to anchor at least one curtainwall unit of a unitized curtainwall system to a floor slab of a building structure. The anchoring system may include an anchor base structure, a slide structure, a hook structure. The anchor base structure may be configured to be attached to the floor slab. The slide structure may be configured to be attached to the at least one curtainwall unit, and the slide structure may include a slide feature with a vertically-oriented length with respect to the at least one curtainwall unit. The hook structure may be configured to be hooked to the anchor base structure. The hook structure may include a slide-receiving feature. The slide-receiving feature and the slide feature of the slide structure may have complementary shapes configured to enable the slide-receiving feature of the hook structure to be slid over the slide feature of the slide structure along the vertically-oriented length of the slide feature.

[0007] In Example 2, the subject matter of Example 1 may optionally be configured such that the complementary shapes of the slide feature and the slide-receiving feature are configured to resist translational and rotational motion of the slide structure with respect to the hook structure in a horizontal plane parallel to a top surface of the floor slab.

[0008] In Example 3, the subject matter of any one or any combination of Examples 1-2 may optionally be configured such that the anchor base structure includes a base feature configured to be attached to the floor slab and a hook-receiving feature configured to be hooked by the hook structure.

[0009] In Example 4, the subject matter of Example 3 may optionally be configured such that the base feature includes a serrated plate configured to be attached to the floor slab, and the hook-receiving feature includes a horizontally-oriented lip parallel to and aligned proximate to an edge of the floor slab when the anchor base structure is attached to the floor slab.

[0010] In Example 5, the subject matter of any one or any combination of Examples 1-4 may optionally be configured such that the slide structure includes an attachment feature configured for use to attach the slide structure to the at least one curtainwall unit.

[0011] In Example 6, the subject matter of Example 5 may optionally be configured such that the attachment feature includes a plate-like structure configured to be fastened to a mullion of the curtainwall unit.

[0012] In Example 7, the subject matter of any one or any combination of Examples 1-6 may optionally be configured such that an x-direction is parallel to a top surface of the floor slab and orthogonal to an edge of the floor slab, a y-direction is parallel to the top surface and parallel to the edge of the floor slab, and a z-direction is orthogonal to the top surface of the floor slab, the slide structure has a centerline in the x-direction, the slide structure has two prongs, and the centerline forms a line of symmetry for the two prongs.

[0013] In Example 8, the subject matter of Example 7 may optionally be configured such that the two prongs have a curved shape and define a recess between the two prongs to receive a central part of the slide-receiving feature of the hook structure.

[0014] In Example 9, the subject matter of Example 8 may optionally be configured such that the two prongs have a threaded sidewall and are configured to receive a threaded fastener that engages the threaded sidewall and contacts the central part of the slide-receiving feature to set a relative position between the slide structure and the hook structure.

[0015] In Example 10, the subject matter of any one or any combination of Examples 8-9 may optionally be configured such that the slide structure further includes a plate with a threaded aperture, the slide structure is configured to receive a shoulder bolt in the recess to thread the shoulder bolt into the threaded aperture of the plate, and a shoulder portion of the shoulder bolt sets a relative position between the slide structure and the hook structure.

[0016] In Example 11, the subject matter of any one or any combination of Examples 7-10 may optionally be configured such that the slide feature has a vertical length in the z-direction and has a plurality of congruent cross-sections parallel to an x-y plane through the vertical length of the slide feature.

[0017] In Example 12, the subject matter of Example 11 may optionally be configured such that the congruent cross-sections of the slide feature have a U-shape.

[0018] In Example 13, the subject matter of any one or any combination of Examples 1-12 may optionally be configured such that the complementary shapes for the slide feature and the slide-receiving feature enable the slide-receiving feature to slide onto the slide feature from an end of the vertically-oriented slide feature and retain the slide-receiving feature from horizontally moving away from the slide feature.

[0019] In Example 14, the subject matter of any one or any combination of Examples 1-13 may optionally be configured such that the anchor base system includes a horizontally-oriented lip parallel to and aligned proximate to an edge of the floor slab when the anchor base structure is attached to the floor slab, and the hook structure includes a hook feature connected to a top of the slide-receiving feature and configured to be hooked over the lip of the anchor base system.

[0020] In Example 15, the subject matter of Example 14 may optionally be configured such that the hook feature includes at least one web formed with a recess configured to receive the lip of the anchor base structure.

[0021] In Example 16, the subject matter of Example 15 may optionally be configured to further include a flange on an end of each of the at least one web.

[0022] In Example 17, the subject matter of any one or any combination of Examples 14-16 may optionally be configured such that the hook feature includes two webs, each of the two webs formed with a recess configured to receive the lip of the anchor base structure, and a threaded fastener is configured to be inserted between the two webs to secure the hook feature to the anchor base structure.

[0023] In Example 18, the subject matter of any one or any combination of Examples 14-17 may optionally be configured such that a vertical length of the slide-receiving feature is longer than a vertical length of the hook feature and is shorter than the vertically-oriented length of the slide feature

[0024] In Example 19, the subject matter of any one or any combination of Examples 1-18 may optionally be configured such that a shape of the hook structure is symmetrical.

[0025] In Example 20, the subject matter of any one or any combination of Examples 1-19 may optionally be configured such that the hook feature has a center line in an x-direction parallel to a top surface of the floor slab and orthogonal to an edge of the floor slab when the hook structure is installed, and the slide-receiving structure has two symmetrical flanking prongs on opposing sides of the center line.

[0026] In Example 21, the subject matter of Example 20 may optionally be configured to further include the two symmetrical flanking prongs define an opening, a distal end of the two symmetrical flanking prongs being closer to each other than other respective portions of the two flanking prongs.

[0027] In Example 22, the subject matter of any one or any combination of Examples 20-21 may optionally be configured such that the slide-receiving structure further includes a central prong on and symmetrical about the center line.

[0028] In Example 23, the subject matter of any one or any combination of Examples 20-22 may optionally be configured such that the two symmetrical flanking prongs have an inside surface defining a recess between the two symmetrical flanking prongs and configured to receive at least two prongs of the slide feature.

[0029] In Example 24, the subject matter of any one or any combination of Examples 20-23 may optionally be configured such that the slide-receiving feature has a vertical length in a z-direction orthogonal to a top surface of the floor slab and has a plurality of congruent cross-sections parallel to an x-y plane through the vertical length, wherein the x-y plane is parallel to the top surface of the floor slab.

[0030] In Example 25, the subject matter of any one or any combination of Examples 1-24 may optionally be configured such that the anchor base structure includes a base feature configured for use to attach the anchor base structure to the floor slab and further includes a hook-receiving feature configured for use to receive the hook structure, the slide structure includes an attachment feature configured for use to attach the slide structure to the at least one curtainwall unit, and the hook structure includes a hook feature configured for hooking the hook-receiving feature of the anchor base structure and further includes a slide-receiving feature.

[0031] An example (e.g., “Example 26”) of an anchoring system configured for use to anchor at least one curtainwall unit of a unitized curtainwall system to a floor slab of a building structure. The anchoring system may include an anchor base structure, a slide structure, and a hook structure. The anchor base structure may include a base feature configured to be attached to the floor slab and a hook-receiving feature configured to be hooked by the hook structure. The slide structure may include an attachment feature configured for use to attach the slide structure to the at least one curtainwall unit, and may include a slide feature with a vertically-oriented length with respect to the at least one curtainwall unit. The hook structure may include a slide-receiving feature. The slide-receiving feature and the slide feature of the slide structure may have complementary shapes configured to enable the slide-receiving feature of the hook structure to be slid over the slide feature of the slide structure along the vertically-oriented length of the slide feature. The hook structure may further include a hook feature connected to a top of the slide-receiving feature and configured to be hooked on the anchor base structure. The complementary shapes of the slide feature and the slide-receiving feature may be configured to resist translational and rotational motion of the slide structure with respect to the hook structure in a horizontal plane parallel to a top surface of the floor slab.

[0032] An example (e.g., “Example 27”) of a method for installing a curtainwall unit may include attaching an anchor base structure to a floor slab, attaching a slide structure to a curtainwall unit where the slide structure including a slide feature with a vertically-oriented length, and sliding a slide-receiving feature of a hook structure over the slide feature and hooking the hook structure to the anchor base structure.

[0033] In Example 28, the subject matter of Example 27 may optionally be configured such that the slide structure is tapped to provide threads within the slide feature, and the method further includes setting a height of the curtainwall unit by setting a relative vertical distance between the slide structure and the hook structure by turning a threaded fastener engaged with the threads of the slide structure into contact with the hook structure.

[0034] In Example 29, the subject matter of Example 27 may optionally be configured such that the slide structure is not tapped such that the slide feature does not have threads and the hook structure includes a raceway, the slide feature and the raceway are configured to receive a threaded fastener, and the method further includes inserting the threaded fastener between the slide feature and the raceway of the hook structure, and turning the threaded fastener into a threaded aperture within a plate between the slide structure to set a relative position between the slide structure and the hook structure using a head of the threaded fastener abutted against the hook structure.

[0035] In Example 30, the subject matter of any one or any combination of Examples 27-29 may optionally be configured to further include turning a threaded fastener into contact with the hook structure and the anchor base structure to secure the hook structure from horizontally moving on the anchor base structure.

[0036] This summary is intended to provide an overview of subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the disclosure. The detailed description is included to provide further information about the present patent application. Other aspects of the disclosure will be apparent to persons skilled in the art upon reading and understanding the following detailed description and viewing the drawings that form a part thereof, each of which are not to be taken in a limiting sense.BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

[0038] FIG. 1 illustrates an example of a curtainwall system.

[0039] FIGS. 2A-2B illustrate an example of a curtainwall installation sequence, including anchoring of a top portion of the curtainwall units to a floor slab.

[0040] FIGS. 3A-3D illustrate perspective views of an example of a curtainwall unit.

[0041] FIGS. 4A-4D illustrate closer views of the periphery of the curtainwall unit illustrated in FIGS. 3A-3D.

[0042] FIGS. 5A-5B illustrate an anchoring system that may be used to attach or anchor a curtainwall unit to a floor slab.

[0043] FIGS. 6A-6B illustrate, by way of example and not limitation, an embodiment of a slide structure.

[0044] FIGS. 7A-7B illustrate, by way of example and not limitation, an embodiment of a hook structure.

[0045] FIG. 8 illustrates, by way of example and not limitation, a top planar view of the slide structure and the hook structure.

[0046] FIG. 9A-9B illustrate, by way of example and not limitation, a sequence for sliding a hook over a slide to onto a lip of an anchor base structure.

[0047] FIG. 10 illustrates, by way of example and not limitation, a method for installing a curtainwall unit.

[0048] FIG. 11 illustrates, by way of example and not limitation, adjacent curtainwall units anchored to a base plate.

[0049] FIGS. 12A-12C illustrate, by way of example and not limitation, various views of a curtainwall anchor system.

[0050] FIGS. 13A-13C illustrate, by way of example and not limitation, various views for an alternative curtainwall anchor design.

[0051] FIG. 14 illustrates, by way of example and not limitation, a perspective, cut-away view of the alternative curtainwall anchor design.

[0052] FIG. 15 illustrates a prior art anchoring system.DETAILED DESCRIPTION

[0053] FIG. 1 illustrates an example of a curtainwall system 100, which may include a plurality of prefabricated curtainwall units 101 that can be quickly installed to provide a building with exterior cladding. Each of the prefabricated curtainwall units 101 may include a vision area 102 and a spandrel area 103. The vision area 102 may provide visual access through the curtainwall. The spandrel area 103 may prevent the floor slab or other parts of the structure from being seen from the exterior of the building. For example, curtainwall units 101 may be formed in rows and columns to form an array of curtainwall units. Thus, a given curtainwall unit may have other units immediately adjacent in a horizontal direction and in a vertical direction. The illustrated building structure is a relatively simple rectilinear shape. Curtainwall systems may be implemented on more complex architectural designs that are not limited to rectilinear shapes.

[0054] FIGS. 2A-2B illustrate an example of a curtainwall installation sequence, including anchoring of a top portion of the curtainwall units to a floor slab. The curtainwall units 201A and 201B may be slid in place next to each other, and provide a sealing fit with each other. Each unit has a main frame that may be formed from extruded aluminum. The vertical frame members may be referred to as vertical mullions, the bottom horizontal frame member may be referred to as a sill, and the top horizontal frame member may be referred to as a gutter. The perimeter framing members of a unitized curtainwall system may be designed with gaskets and male / female mating aluminum extrusions which, when fitted together, create an air and water barrier between the interior and exterior. The curtainwall units may be attached or anchored to the floor slab 204 using an anchoring system. For example, the curtainwall units may hang on anchor bases such as the brackets 205 illustrated in FIGS. 2A-2B. FIG. 2A also illustrates a cartesian coordinate system, where an x-direction is parallel to a top surface of the floor slab and orthogonal to an edge of the floor slab, a y-direction is parallel to the top surface and parallel to the edge of the floor slab, and a z-direction is orthogonal to the top surface of the floor slab. This cartesian coordinate system may be used to assist with identifying orientations of different components of the anchoring system illustrated below (e.g., see slide structure in FIG. 6B and hook structure of FIGS. 7A-7B).

[0055] FIGS. 3A-3D illustrate perspective views of an example of a curtainwall unit 301. The curtainwall unit 301 may include vertical mullions 306A and 306B, a sill 307, and a gutter 308. By way of example and not limitation, the curtainwall unit may also include gaskets used to form an air seal 309, a water seal 310, and a rainscreen 311. The water seal 310 and the air seal 309 may be water-tight. The rainscreen 311 may not be water-tight. The curtain wall unit 301 may also include a vision area 302 and a spandrel area 303. The gutter 308 may facilitate the drainage of fluid from an area between the air seal 309 and water seal 310 to the exterior in front of the installed curtainwall system. The air seal 309 may extend along a perimeter of the curtainwall unit 301 and may form an air seal gasket line. Putty, such as a silicone putty plug may be used to supplement the air seal 309, such as where gaps exist between adjacent curtainwall units 301. The water seal 310 may extend along a perimeter of the curtainwall unit 301 and may form a water seal gasket line. The water seal 310 may provide a watertight joint. The rainscreen 311 may extend along a perimeter of the curtainwall unit 301 and may form a rainscreen gasket line. The rainscreen may be designed with gaps in the rainscreen gasket line to allow water to weep out to the exterior, and to allow pressure equalization of interior cavities of the curtainwall system 100. In an installed system, adjacent units may form a front cavity between the rainscreen 311 and the water seal 310 and a rear cavity between the water seal 310 and the air seal 309.

[0056] FIGS. 4A-4D illustrate closer views of the periphery of the curtainwall unit illustrated in FIGS. 3A-3D. FIG. 4A illustrates a view of a top left portion of the curtainwall unit 401, FIG. 4B illustrates a view of a top right portion of the curtainwall unit, FIG. 4C illustrates a bottom left view of a curtainwall unit, and FIG. 4D illustrates a bottom right view of a curtainwall unit. The curtainwall unit 401 may include an air seal gasket 409, a plastic isolator 412, a horizontal gutter 408, a water barrier gasket 410, a male mullion 406B, a rainscreen gasket 411, a plastic blade 413, a gasket 414, a female mullion 406A, a protected vertical chamber 415, a plastic thermal shield 416, and a horizontal sill 407. The horizontal gutter 408 may also be referred to as a horizontal frame member. The horizontal gutter 408 may include the rear channel 418 formed between the air seal gasket 409 and the water barrier gasket 410. Additional detail may be found in U.S. patent application Ser. No. 16 / 018,520, filed on Jun. 26, 2018, now abandoned, and U.S. patent application Ser. No. 16 / 909,033, filed Jun. 23, 2020, now issued as U.S. Pat. No. 11,313,122, both of which are entitled “Unitized Curtainwall Systems and Methods” and are incorporated herein by reference in their entirety.

[0057] FIGS. 5A-5B illustrate an anchoring system that may be used to attach or anchor a curtainwall unit to a floor slab. According to various embodiments of the present subject matter, the anchoring system 520 may include an anchor base structure 521, a slide structure 522, and a hook structure 523. For example, the components of the anchoring system 520 may be formed from extruded aluminum. The anchor base structure 521 may be configured to be attached to the floor slab, and the slide structure 522 may be configured to be attached to the curtainwall unit(s) 501. The hook structure 523 may be configured to be hooked to the anchor base structure 521. As will be discussed in more detail below, a portion of the hook structure 523 may be configured to slide over a portion of the slide structure 522. A fastener, such as a screw, may be used to secure the relative position between the hook structure 523 and the slide structure 522. As the hook structure 523 is attached to the anchor base structure 521 on the floor slab and the slide structure 522 is attached to the curtainwall unit, the positioning of the curtainwall unit with respect to the floor slab may be adjusted by adjusting the relative position between the hook structure 523 and the slide structure 522. The curtainwall unit 501 is lower with respect to the anchor based structure 521 in FIG. 5A than it is in FIG. 5B. Thus, the anchoring system is capable of accommodating variations in the floor-to-floor heights.

[0058] FIGS. 6A-6B illustrate, by way of example and not limitation, an embodiment of a slide structure. The illustrated slide structure 622 includes a slide feature 624 and further includes an attachment feature 626 used to connect the slide structure 622 to the curtainwall unit. The slide structure 622 may be formed as a unitary structure with both the attachment feature 626 and the slide feature 624. The illustration includes a demarcation line 627 to assist with identifying these features. For example, the attachment feature 626 may be a plate-like structure that can be fastened along a side of the curtainwall unit (e.g., fastened to a mullion of the curtainwall unit). The illustrated attachment feature 626 includes screw holes 628 through which screws may be inserted into the mullion. The plate-like structure may have opposing faces with profiles that cooperate with the profiles of the side of the curtainwall unit.

[0059] A centerline 629 of the slide structure 622 may be in the x-direction, where the x-direction is parallel to the top surface of the floor slab and orthogonal to its edge. The centerline 629 may bisect the plate-like structure of the attachment feature 626. The slide structure 622 may include two prongs 630, with the centerline 629 serving as a line of symmetry for these prongs. The prongs 630 may be designed with a curved shape, forming a recess between them to accommodate a central part of the slide-receiving feature of the hook structure (e.g., central prong 848 of the slide receiving feature 825 illustrated in FIG. 8). The prongs 630 may form part of a circular aperture. For example, a partial circular aperture may be sized to receive a screw.

[0060] The prongs 630 may have a threaded sidewall such that the partial circular aperture is a threaded aperture configured to receive a threaded fastener such as a set screw. In some embodiments, this set screw may engage the threaded sidewall and contact the central part (e.g., central prong 848 illustrated in FIG. 8) of the slide-receiving feature, thereby setting a relative position between the slide structure and the hook structure.

[0061] The slide feature 624 of the slide structure 622 may extend vertically (z-direction) and may have a plurality of congruent cross-sections parallel to the x-y plane throughout its vertical length 631. The slide feature 624 may have identical top and bottom ends with flat, parallel faces corresponding to the congruent cross-sections. These cross-sections may have a U-shape. This configuration allows the slide-receiving feature of the hook structure to slide onto the slide feature 624 from an end of the vertically-oriented slide feature. Horizontal movement of the hook structure away from the slide feature is prevented by the cooperating shapes of the slide feature and the slide-receiving feature.

[0062] FIGS. 7A-7B illustrate, by way of example and not limitation, an embodiment of a hook structure. The hook structure 723 may include a slide receiving feature 725, and may include a hook feature 732 that connects to the top of the slide-receiving feature 725. The hook structure 723 may be formed as a unitary structure with both the slide receiving feature 725 and the hook feature 732 as integral components. The illustration includes a demarcation line 733 to assist with identifying these features in the unitary structure.

[0063] The anchor base structure may include a horizontally-oriented lip (e.g., lip 952 in FIGS. 9A-9B) aligned parallel to and aligned proximate to the edge of the floor slab. The hook feature 732 may be designed to engage with the lip of the anchor base system, providing a secure connection. For example, the hook feature 732 may include at least one web 734 with a recess 735 configured to accommodate the lip of the anchor base structure. The web(s) 734 may be elongated structures with a width in the y-direction that is smaller than the length in the x-direction or the height in the z-direction. Each web 734 may also include a flange 736 at its end to enhance stability when hooked on the anchor base system. The hook feature 732 may include two webs 734, each formed with a recess 735 to receive the lip. The webs 734 may be parallel webs. A threaded fastener, such as a set screw, may be inserted between the webs 734 to secure the hook feature 732 to the anchor base structure and thereby resist horizontal movement (see set screw 1164 engaging the horizontally-oriented lip 1152 in FIG. 11).

[0064] The slide-receiving feature 725 of the hook structure 723 may be configured with a vertical length 737 that is longer than the vertical length 738 of the hook feature 732 but shorter than the vertically-oriented length 631 of the slide feature 624. Thus, the slide feature 624 may slide within the slide-receiving feature of the hook structure to change the relative position of the curtainwall unit to the floor slab. The hook structure 723 may have a symmetrical shape, with a center line of symmetry 739 in the x-direction. The sidewall surfaces of the slide feature 624 and the slide-receiving feature 725 are parallel to the z-axis. For example, the slide-receiving feature 725 of the hook structure may extend for a vertical length 737 in the z-direction. The slide-receiving feature 725 may be formed with a plurality of congruent cross-sections parallel to the x-y plane throughout its vertical length 737. That is, the cross-sections have an equal size and shape through the vertical length 737 of the slide-receiving feature 725. The slide-receiving feature 725 may have identical top and bottom ends with flat, parallel faces corresponding to the congruent cross-sections. The cross-sections of the slide-receiving feature 725 and the cross-sections of the slide feature 624, which have a plurality of congruent cross-sections parallel to the x-y plane, have a consistent size and shape to enable the vertical motion of the slide-receiving feature 725 over the slide feature 624.

[0065] FIG. 8 illustrates, by way of example and not limitation, a top planar view of the slide structure and the hook structure. Both of the slide structure and the hook structure may be formed as a unitary structure, with different features forming part of the unitary structure. The hook structure 823 may include a slide-receiving feature 825 and a hook feature 832, as separated by the demarcation line 833, and the slide structure 822 may include a slide feature 824 and an attachment feature 826, as separated by the demarcation line 827.

[0066] The attachment feature 826 may be a plate-like structure that can be fastened to a mullion of the curtainwall unit. The plate-like structure may have opposing faces 840 with profiles that cooperate with the profiles of the side of the curtainwall unit. These profile features may help secure the attachment of the slide structure 822 to the curtainwall unit, as it will it will resist motion in the x-direction orthogonal to the face of the floor slab. Furthermore, the attachment feature 826 may include a shoulder 841 that defines a corner 842 that is placed against an edge of the mullion to further secure the curtainwall unit.

[0067] The slide structure 822 may include two prongs 830, with the centerline 829 serving as a line of symmetry for these prongs. The prongs 830 may be designed with a curved shape, forming a recess 843 between them to accommodate a central part of the slide-receiving feature 825 of the hook structure 823. The prongs 830 may form part of a cylindrical aperture which may be sized to receive a screw. The slide structure 822 may be viewed as having a partially-annular shape, with an opening into the center part of the shape to accommodate the central part of the slide-receiving feature 825 of the hook structure 823. The prongs 830 may have a threaded sidewall 844 such that the partial circular aperture is a threaded aperture configured to receive a threaded fastener such as a set screw. In some embodiments, this set screw may engage the threaded sidewall and contact the central part of the slide-receiving feature to thereby set a relative position between the slide structure and the hook structure.

[0068] The slide feature 824 of the slide structure 822 may extend vertically (z-direction) and may have a plurality of congruent cross-sections parallel to the x-y plane throughout its vertical length. These cross-sections may have a U-shape. This configuration allows the slide-receiving feature 525 of the hook structure 823 to slide onto the slide feature 824 from an end of the vertically-oriented slide feature 824. Horizontal movement of the hook structure away from the slide feature is prevented by the cooperating shapes of the slide feature and the slide-receiving feature. The cooperating shapes of the slide feature 824 and the slide-receiving feature 825 may enable to the slide feature 824 to be keyed into the slide-receiving feature 825 of the hook structure 823. The slide-receiving feature 825 may include two symmetrical flanking prongs 845 on opposing sides of this centerline 829, defining an opening.

[0069] These flanking prongs may be configured such that the distal ends 846 of these prongs 845 are closer to each other than other portions and correspond to fitting around a neck 847 of the slide structure 822, to thereby provide a secure fit when the slide-receiving feature 825 is slid over an end of the slide feature 824. The inside surfaces of the two symmetrical flanking prongs 845 define a recess between them, which may be configured to receive the at least two prongs 830 of the slide feature 824.

[0070] The slide-receiving feature 825 of the hook structure 823 may also include a central prong 848 that is symmetrical about the centerline 829. The central prong 848 may have a cross-sectional shape (e.g., circular) to be received in the recess 843 between the prongs 830 of the slide feature 824. The prongs 830 may be configured such that the distal ends 849 of these prongs 830 are closer to each other than other portions and correspond to fitting around a neck of the central prong 848, to thereby provide a secure fit when the slide-receiving feature 825 is slide over an end of the slide feature 824. The outside wall of the prongs 830 of the slide structure 822 and the inside wall of the flanking prongs 845 of the hook structure 823 may have features, such as straight walls that form profile notches 850 that may be resist rotation in an x-y plane of the slide feature within the slide-receiving feature.

[0071] The hook feature 832 may be designed to engage with a lip of the anchor base system, providing a secure connection. For example, the hook feature 832 may include parallel webs 834 with a recess configured to accommodate the lip of the anchor base structure. The web(s) 834 may be elongated structures with a width in the y-direction that is smaller than the length in the x-direction or the height in the z-direction. The webs 834 may also include a flange 836 at its end to enhance stability when hooked on the anchor base system. A threaded fastener such as set screw may be inserted between the webs 834 to secure the hook feature 832 to the anchor base structure and thereby resist horizontal movement, which shown and discussed in more detail with respect to FIG. 11.

[0072] For purposes of comparison, a prior art anchoring system is illustrated in FIG. 15. The prior art anchoring system includes a base plate 1566 that can be attached to a building structure. The base plate 1566 has a lip 1567. A hook 1568 is hooked over the lip 1567 of the base plate 1566. The position of the hook 1568 on the base plate 1566 may be set using screws 1570 through screw holes 1571. A slide 1569 is attached to the edge of the curtainwall unit. The shape of the slide structure 822 and the hook structure 823 of the present subject matter is different from the shape of the slide 1569 and hook 1568 in the illustrated prior art anchoring system.

[0073] FIG. 9A-9B illustrate, by way of example and not limitation, a sequence for sliding a hook over a slide to onto a lip of an anchor base structure. An anchor base structure 921 is fastened to the floor slab 904 to provide a stable foundation. In the illustration, the floor slab 904 is formed with a recess, and the anchor base structure 921 may be fasted to the floor slab 904 within this recess. The anchor base structure 921 may have a base feature 951 configured to be attached to the floor slab 904 and a hook-receiving feature 952 configured to be hooked by the hook structure. The anchor base structure 921 may be formed as a unitary structure with both the base feature 951 and the hook-receiving feature 952. The base feature 951 may be a plate that has slots 953. Bolts 954 in the floor slab 904 may extend through the slots 953. The slots 953 may be perpendicular to the side edge of the floor slab. The base feature 951 may be a serrated plate, and serrated washers 955 may be used between a nut 956 and the serrated plate to securely fasten the plate when the nut is tightened onto the bolt. The hook-receiving feature 952 may include a horizontally-oriented lip that is aligned parallel to and positioned near the edge of the floor slab 904.

[0074] The slide structure 922 includes a slide feature 924 with a vertically-oriented length. The hook structure 923 includes a slide-receiving feature 925. The slide-receiving feature 925 and the slide feature 924 have complementary shapes configured to enable the slide-receiving feature 925 of the hook structure 923 to be slid over the slide feature 924 of the slide structure 922 along the vertically-oriented length of the slide feature. The hook structure 923 further including a hook feature configured to be hooked on the anchor base structure 921. The complementary shapes of the slide feature 924 and the slide-receiving feature 925 are configured to resist translational and rotational motion of the slide structure with respect to the hook structure in a horizontal plane parallel to a top surface of the floor slab.

[0075] A curtainwall unit 901 may be placed against the side of the building structure, and a hook structure 923 may be slid over the slide structure 922 until the hook structure 923 hooks on the hook-receiving feature 952 (e.g., lip) of the anchor base structure 921, as illustrated in FIG. 9B.

[0076] The anchoring system is designed to accommodate adjustments in three orthogonal directions, promoting alignment and stability of the curtainwall units. The anchor base structure 921 may be a slotted base plate with a lip. An adjustment perpendicular to the building face (x-direction) is possible using the slotted base plate to attach the lip of the base plate at a prescribed distance from the slab edge. The slotted base plate may be positioned over bolts in the floor slab, and nuts may be screwed onto the bolts to fasten the base plate in position. The base plate may include serrations, which may interface with a serrated washer, to securely position the base plate at the prescribed position. Adjustments in the y-direction (left-right) may be accommodated by the width of the base plate. The hook structures may be designed to land on the center of the base plate, but the engineered width allows for off-center positioning to accommodate construction tolerances. Adjustments in the z-direction (perpendicular to a top surface of the floor slab) may be made using a threaded fastener such as a set screw within the threaded portion of the anchor slide. The elevation of the curtainwall assembly can be adjusted, and thus the vertical positioning of the curtainwall unit may be precise. Turning the screw into the threaded portion of the anchor slide pushes the center portion of the anchor structure further down, which raises the anchor slide and thus raises the curtain wall unit. Turning the screw out of the threaded portion of the anchor slide allows the center portion of the anchor structure to be higher, which lowers the anchor slide and thus lowers the curtain wall unit.

[0077] The anchoring system separates the load paths for wind loads and dead loads, allowing for independent sizing based on project conditions. The dead load, or gravitational force from the weight of the curtainwall panel, is supported by the threaded fastener (e.g., set screw) within the anchor slide. This screw resists forces along its threads and is supported by the top of the anchor hook which slides into the anchor slide. The hook is then supported by the anchor base plate.

[0078] The wind load, or forces perpendicular to the face of the curtainwall panel, is supported through the anchor slide and hook. The outside arms of the hook wrap around the slide profile to resist wind forces. The shape of the slide-receiving feature and the slide feature retain the slide-receiving feature from horizontally moving away from the slide feature. The system is designed to resist forces parallel to the face of the slab, such as seismic or racking forces. A fastener passes through the center of the anchor hook and into the base plate, allowing a single fastener to absorb forces from both directions.

[0079] FIG. 10 illustrates, by way of example and not limitation, a method for installing a curtainwall unit. At 1057, an anchor base structure is attached to a floor slab. At 1058, a slide structure is attached to a curtainwall unit. The slide structure may a slide feature with a vertically-oriented length. The slide structure may be attached to the curtainwall unit off site or on-site before the curtainwall unit is positioned for installation. At 1059, a slide-receiving feature of a hook structure may be slid over the slide feature. At 1060, the hook structure may be hooked to the anchor base structure. At 1061, a threaded fastener such as a set screw may be screwed into contact with the hook structure and the anchor base structure to secure the hook structure from horizontally moving on the anchor base structure. For example, the set screw may be screwed between the webs of the hook structure until the screw contacts the anchor base structure (e.g., the lip). At 1062, a height of the curtainwall unit may be set by setting a relative vertical distance between the slide structure and the hook structure. A screw engaged with threads of the slide structure may be turned into contact with the hook structure.

[0080] FIG. 11 illustrates, by way of example and not limitation, adjacent curtainwall units anchored to a base plate. An anchor base structure 1121 is fastened to the floor slab 1104. The anchor base structure 1121 may be formed as a unitary structure having a base feature 1151 configured to be attached to the floor slab 904 and a hook-receiving feature 1152 configured to be hooked by the hook structure. The base feature 1151 may be a serrated plate that has slots 1153, and bolts 1154 in the floor slab 1104 may extend through the slots 1153. Serrated washers 1155 may be used between a nut 1156 and the serrated plate to securely fasten the plate when the nut 1156 is tightened onto the bolt 1154. The hook-receiving feature 1152 may be a horizontally-oriented lip that is aligned parallel to and positioned near the edge of the floor slab 1104.

[0081] The slide feature 1124 is illustrated as being engaged with the slide-receiving feature 1125 after the slide-receiving feature 1125 of the hook structure 1123 is slid over the slide feature 1124. The hook structure 1123 further includes a hook feature configured to be hooked over the lip 1152 on the anchor base structure 1121. Adjustments in the z-direction (perpendicular to a top surface of the floor slab) may be made using a threaded fastener such as a set screw 1163 within the threaded portion of the anchor slide. The elevation of the curtainwall assembly can be adjusted, and thus the vertical positioning of the curtainwall unit may be precise. Turning the screw 1163 into the threaded portion of the anchor slide pushes the center portion of the anchor structure further down, which raises the anchor slide and thus raises the curtain wall unit. Turning the screw out of the threaded portion of the anchor slide allows the center portion of the anchor structure to be higher, which lowers the anchor slide and thus lowers the curtain wall unit. The anchoring system separates the load paths for wind loads and dead loads, allowing for independent sizing based on project conditions. The dead load, or gravitational force from the weight of the curtainwall panel, is supported by the set screw 1163 within the anchor slide. This screw 164 resists forces along its threads and is supported by the top of the anchor hook which slides into the anchor slide. Another set screw 1164 may be used to secure the hook structure 1123 to the lip 1152 of the anchor base structure 1121.

[0082] FIGS. 12A-12C illustrate, by way of example and not limitation, various views of a curtainwall anchor system. FIG. 12A is a top view, and FIG. 12B is a cross-section view taken along line A-A in FIG. 12A. FIG. 12C is an exploded perspective view of the curtainwall anchor system. These figures illustrate the anchor base structure 1221, the hook structure 1223 and the slide structure 1222 including the attachment feature 1226 of the slide structure 1222 attached to the curtain wall unit 1201. These figures also illustrate the slide-receiving feature of the hook structure 1223 slid onto the slide feature 1224 of the slide structure 1222. Each slide feature 1224 may be tapped through the length of the slide. A threaded fastener such as a set screw 1263 may be inserted into the tapped slide feature 1224 to a desired height. The hook structure 1223 bears up on the underside of the set screw 1263. Turning the set screw changes the elevation (e.g., lift or lowers) the curtainwall unit.

[0083] FIGS. 13A-13C illustrate, by way of example and not limitation, various views for an alternative curtainwall anchor design. FIG. 13A is a top view, and FIG. 13B is a cross-section view taken along line A-A in FIG. 13A. FIG. 13C is an exploded perspective view of the curtainwall anchor system. These figures illustrate the anchor base structure 1321, the hook structure 1323 and the slide structure 1322 including the attachment feature 1326 of the slide structure 1322 attached to the curtainwall unit 1301A. Another curtainwall unit 1301B may be installed over the curtainwall unit 1301A, as generally illustrated in FIGS. 2A-2B. The slide-receiving feature of the hook structure 1323 is slid onto the slide feature 1324 of the slide structure 1322. The figure also illustrates a threaded fastener such as a set screw 1364 securing the hook structure 1323 into the lip of the anchor base structure 1321. In this alternative curtainwall anchor design, the slide structure 1322 is not tapped to provide a threaded slide structure, and a plate 1365 with a threaded aperture is attached to an end (e.g., bottom end) of the slide structure 1322. The hook structure 1323 may be configured with a raceway into which a fastener such as a shoulder bolt or a long cap screw 1363 is inserted. Both the shoulder bolt and cap screw have relatively large heads. A cap screw has threads along the length of the shaft, and a shoulder bolt may only have threads along a partial length of the shaft such as near the end of the shaft. A shoulder bolt or long cap screw 1363 may be screwed into the threaded aperture of the plate 1365 with its shoulder portion setting the relative vertical position between the slide structure 1322 and the hook structure 1323. That is, as the fastener turns and screws into or out of the threaded plate, the threaded plates 1365 moves up or down changing its elevation.

[0084] FIG. 14 illustrates, by way of example and not limitation, a perspective, cut-away view of the alternative curtainwall anchor design. The figure illustrates the anchor base structure 1421, the hook structure 1423 and the slide structure 1422 attached to the curtainwall unit 1401A. Another curtainwall unit 1401B may be installed over the curtainwall unit 1401A, as generally illustrated in FIGS. 2A-2B. The anchor base structure 1421 may be designed with a serrated plate and to be attached to the floor slab using bolts 1454, serrated washers 1455, and nuts 1456. The serrated design of the plate and washers enables a secure grip between the washers and the plate. The anchor base structure 1421 has a lip 1452 on which the hook structures 1423 are hooked. The slide structure 1422 includes an attachment feature, a slide feature 1424, and a plate 1465 with a threaded aperture attached to the bottom of the slide feature 1424. A threaded fastener such as a cap screw or a shoulder bolt 1463 extends through the threaded aperture of the plate 1465. A head of the fastener abuts against the hook structure 1423 The relative vertical position between the slide structure 1422 and the hook structure 1423 may be adjusted by turning the shoulder bolt 1463.

[0085] The terms horizontal and vertical have been used to describe an orientation over various components of the curtainwall system and the anchor system. These terms are intended to convey the orientation of the components when they are installed as designed on the building. However, if used within the claims, these terms, in and of themselves, do not require the components to be installed on the building to infringe.

[0086] The above detailed description is intended to be illustrative, and not restrictive. The scope of the disclosure should, therefore, be determined with references to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

1. An anchoring system configured for use to anchor at least one curtainwall unit of a unitized curtainwall system to a floor slab of a building structure, the anchoring system including:an anchor base structure configured to be attached to the floor slab;a slide structure configured to be attached to the at least one curtainwall unit, the slide structure including a slide feature with a vertically-oriented length with respect to the at least one curtainwall unit; anda hook structure configured to be hooked to the anchor base structure, the hook structure including a slide-receiving feature, the slide-receiving feature and the slide feature of the slide structure having complementary shapes configured to enable the slide-receiving feature of the hook structure to be slid over the slide feature of the slide structure along the vertically-oriented length of the slide feature.

2. The anchoring system of claim 1, wherein the complementary shapes of the slide feature and the slide-receiving feature are configured to resist translational and rotational motion of the slide structure with respect to the hook structure in a horizontal plane parallel to a top surface of the floor slab.

3. The anchoring system of claim 1, wherein the anchor base structure includes a base feature configured to be attached to the floor slab and a hook-receiving feature configured to be hooked by the hook structure.

4. The anchoring system of claim 3, wherein:the base feature includes a serrated plate configured to be attached to the floor slab; andthe hook-receiving feature includes a horizontally-oriented lip parallel to and aligned proximate to an edge of the floor slab when the anchor base structure is attached to the floor slab.

5. The anchoring system of claim 1, wherein the slide structure includes an attachment feature comprising a plate-like structure configured to be fastened to a mullion of the at least one curtainwall unit.

6. The anchoring system of claim 1, wherein:an x-direction is parallel to a top surface of the floor slab and orthogonal to an edge of the floor slab, a y-direction is parallel to the top surface and parallel to the edge of the floor slab, and a z-direction is orthogonal to the top surface of the floor slab; andthe slide structure has a centerline in the x-direction, the slide structure has two prongs, and the centerline forms a line of symmetry for the two prongs.

7. The anchoring system of claim 6, wherein the two prongs have a curved shape and define a recess between the two prongs to receive a central part of the slide-receiving feature of the hook structure.

8. The anchoring system of claim 7, wherein the two prongs have a threaded sidewall and are configured to receive a threaded fastener that engages the threaded sidewall and contacts the central part of the slide-receiving feature to set a relative position between the slide structure and the hook structure.

9. The anchoring system of claim 7, wherein the slide structure further includes a plate with a threaded aperture, the slide structure is configured to receive a shoulder bolt in the recess to thread the shoulder bolt into the threaded aperture of the plate, and a shoulder portion of the shoulder bolt sets a relative position between the slide structure and the hook structure.

10. The anchoring system of claim 6, wherein the slide feature has a vertical length in the z-direction and has a plurality of congruent cross-sections parallel to an x-y plane through the vertical length of the slide feature, wherein the plurality of congruent cross-sections have a U-shape.

11. The anchoring system of claim 1, wherein the anchor base structure includes a horizontally-oriented lip parallel to and aligned proximate to an edge of the floor slab when the anchor base structure is attached to the floor slab, and the hook structure includes a hook feature connected to a top of the slide-receiving feature and configured to be hooked over the lip of the anchor base structure.

12. The anchoring system of claim 11, wherein the hook feature includes at least one web formed with a recess configured to receive the lip of the anchor base structure, and each of the at least one web includes an end with a flange.

13. The anchoring system of claim 11, wherein the hook feature includes two webs, each of the two webs formed with a recess configured to receive the lip of the anchor base structure, and a threaded fastener is configured to be inserted between the two webs to secure the hook feature to the anchor base structure.

14. The anchoring system of claim 11, wherein a vertical length of the slide-receiving feature is longer than a vertical length of the hook feature and is shorter than the vertically-oriented length of the slide feature.

15. The anchoring system of claim 11, wherein the hook feature has a center line in an x-direction parallel to a top surface of the floor slab and orthogonal to an edge of the floor slab when the hook structure is installed, the slide-receiving feature has two symmetrical flanking prongs on opposing sides of the center line defining an opening, and a distal end of each of the two symmetrical flanking prongs is closer to the other than other respective portions of the two flanking prongs.

16. The anchoring system of claim 15, wherein the two symmetrical flanking prongs have an inside surface defining a recess between the two symmetrical flanking prongs and configured to receive at least two prongs of the slide feature.

17. An anchoring system configured for use to anchor at least one curtainwall unit of a unitized curtainwall system to a floor slab of a building structure, the anchoring system including an anchor base structure, a slide structure and a hook structure, wherein:the anchor base structure includes a base feature configured to be attached to the floor slab and a hook-receiving feature configured to be hooked by the hook structure;the slide structure includes an attachment feature configured for use to attach the slide structure to the at least one curtainwall unit, and includes a slide feature with a vertically-oriented length with respect to the at least one curtainwall unit;the hook structure includes a slide-receiving feature, the slide-receiving feature and the slide feature of the slide structure having complementary shapes configured to enable the slide-receiving feature of the hook structure to be slid over the slide feature of the slide structure along the vertically-oriented length of the slide feature, the hook structure further including a hook feature connected to a top of the slide-receiving feature and configured to be hooked on the anchor base structure; andthe complementary shapes of the slide feature and the slide-receiving feature are configured to resist translational and rotational motion of the slide structure with respect to the hook structure in a horizontal plane parallel to a top surface of the floor slab.

18. A method for installing a curtainwall unit, comprising:attaching an anchor base structure to a floor slab;attaching a slide structure to a curtainwall unit, the slide structure including a slide feature with a vertically-oriented length; andsliding a slide-receiving feature of a hook structure over the slide feature and hooking the hook structure to the anchor base structure.

19. The method of claim 18, wherein the slide structure is tapped to provide threads within the slide feature, the method further comprising setting a height of the curtainwall unit by setting a relative vertical distance between the slide structure and the hook structure by turning a threaded fastener engaged with the threads of the slide structure into contact with the hook structure.

20. The method of claim 18, further comprising turning a threaded fastener into contact with the hook structure and the anchor base structure to secure the hook structure from horizontally moving on the anchor base structure.

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