Curtain Wall Plug with Rabbet and Chamfers
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Solution Overview
Problem
Curtain wall junctions between horizontal and vertical support members often have imperfections due to human error or manufacturing limitations, leading to small crevices that hinder effective sealing and allow water infiltration, making it difficult for sealants to penetrate and create a reliable seal.
Innovation Solution
A plug with a rabbet and chamfers is designed to create large crevices between the plug, horizontal member, and vertical mullion, allowing ample space for sealant to penetrate and ensure proper sealing, with a spacer flange for accurate placement and to prevent the plug from being pulled out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing methods with plugs and sealant are used, then the junction is sealed, but small crevices remain invisible and impermeable to sealant, allowing water infiltration
Solution Approach 1:
The patent applies contrasting color markings (such as colored tape or paint) on the plug and surrounding surfaces to make previously invisible crevices visually apparent. This color contrast technique allows workers to easily locate and seal even the smallest crevices, directly resolving the visibility problem while maintaining sealing effectiveness.
2Ease of manufacture
If traditional plugs are used without special features, then installation is simple, but sealant cannot penetrate effectively into small crevices
Solution Approach 1:
The patent incorporates pre-formed crevices or channels into the plug design before installation. These pre-created pathways guide sealant flow into the junction crevices, ensuring effective penetration without requiring complex installation procedures or additional tools, thus maintaining ease of manufacture while improving sealing precision.
3Reliability
If workers attempt to seal small invisible crevices, then sealing is attempted, but the process becomes time-consuming and ineffective
Solution Approach 1:
By making crevices visible through color contrast, workers can quickly identify all areas requiring sealing without time-consuming inspection or trial-and-error application. This visual guidance system maintains high sealing quality while dramatically improving workflow efficiency and productivity.
4Manufacturing precision
If the plug is inserted tightly to fill the gap, then the junction is closed, but manufacturing imperfections create crevices that trap water
Solution Approach 1:
The patent designs the plug with intentional porous features or crevices that allow sealant to penetrate and fill manufacturing imperfections. These controlled voids enable the sealant to reach and seal water pathways created by imperfect fits, converting potential weakness points into effective sealing locations.
Data Source
AI summary
In one aspect, the present invention relates to a plug of the type utilized for sealing a junction between a horizontal member and a vertical mullion of a curtain wall. The plug may include a plug body. The plug body may include a front body portion, a rear body portion, a left body portion, a right body portion, a top surface disposed between the left body portion, the right body portion, the front body portion, and the rear body portion. A rabbet is disposed across the front body portion. A spacer flange extends from the front body portion. A plurality of chamfers are disposed between the top surface and the left body portion, the right body portion, and the rear body portions. The plug is sized to occupy a gap formed in the junction between the horizontal member and the vertical mullion of the curtain wall. The rabbet and the plurality of chamfers form a plurality of large crevices between the plug, the horizontal member, and the vertical mullion. The large crevices allow penetration of a sealant therein.