Curtain wall system and components thereof

A mullion assembly for securing at least one first panel in a predetermined position relative to at least one second panel on a building structure between the building structure and an external space, the mullion assembly comprising:

• a first mullion segment of said at least one first panel, the first mullion segment comprising:
• an elongate first main portion extending between inner and outer ends thereof;
• an elongate first inner portion attached to the first main portion at the inner end and extending substantially orthogonally from the main portion, the first inner portion defining an inner aperture therein;
• a first outer portion attached to the first main portion at the outer end and extending substantially orthogonally from the main portion, the first outer portion defining an outer aperture therein;
• said at least one first panel comprising a first glazing unit secured to the first outer portion and at least partially positioned between the external space and the first outer portion;
• a second mullion segment of said at least one second panel installed on the building structure, the second mullion segment comprising:
• an elongate second main portion extending between inner and outer ends thereof;
• an elongate second inner portion attached to the second main portion at the inner end and extending substantially orthogonally from the main portion, the second inner portion comprising an inner peg at least partially receivable in the inner aperture of the first inner portion;
• a second outer portion attached to the second main portion at the outer end and extending substantially orthogonally from the main portion, the second outer portion comprising an outer peg at least partially receivable in the outer aperture;
• said at least one second panel comprising a second glazing unit secured to the second outer portion and at least partially positioned between the external space and the second outer portion;
• upon the inner peg and the outer peg being at least partially received in the inner and outer apertures respectively, to attach the first and second inner portions together and to attach the first and second outer portions together respectively, the first and second mullion segments are attached to each other, securing said at least one first panel in the predetermined position relative to the building structure, and defining a central cavity in which a central volume of air is isolated for at least partially thermally insulating the building structure relative to the external space, the first and second outer portions collectively defining a boundary region between the central cavity and the exterior space;
• and
• at least one thermal insulator element at least partially positionable between said at least one first panel and said at least one second panel, to at least partially define at least one thermal break between the external space and the boundary region.

A transverse mullion assembly for securing a first panel in a preselected position relative to a second panel on a building structure between the building structure and an external space, the transverse mullion assembly comprising:

• a first transverse mullion segment comprising:
• an elongate first main transverse portion extending between inner and outer ends thereof;
• the first main transverse portion comprising a first body segment comprising first front and rear walls and at least one first side wall at least partially defining a transverse central region in which a transverse central volume of air is isolated for thermally insulating the building structure relative to the external space;
• a first outer portion attached to the first main transverse portion at the outer end and extending substantially orthogonally from the first main transverse portion;
• the first outer portion and the front wall defining a slot therebetween;
• the first panel comprising a first glazing unit secured to the first outer portion and at least partially positioned between the external space and the first outer portion;
• a second transverse mullion segment comprising:
• an elongate second main transverse portion extending between inner and outer ends thereof;
• the second main transverse portion comprising a second body segment comprising second front and rear walls and at least one second side wall at least partially defining a second central region in which a second central volume of air is isolated for thermally insulating the building structure relative to the external space;
• the second body segment comprising a second outer portion positioned outwardly relative to the second central region;
• an arm subassembly attached to the second main transverse portion and comprising an arm extending substantially orthogonally from a base of the arm subassembly secured to the second side wall of the second main transverse portion, the arm being at least partially receivable in the slot in a secured position in which the arm is sealably engaged with the first outer portion and the first front wall;
• the second panel comprising a second glazing unit secured to the second outer portion and at least partially positioned between the external space and the second outer portion;
• a gasket at least partially positionable between the first and second transverse mullion segments between the arm and the external space when the arm is in the secured position in the slot to at least partially thermally insulate the building structure relative to the external space;
• when the arm is in the secured position in the slot, the first and second outer portions and the arm define a separation region between the transverse central region and the external space;
• and
• at least one transverse thermal insulator element at least partially positionable between the first and second panels, to at least partially define at least one thermal break between the external space and the separation region.

An intermediate mullion assembly for securing an upper panel and a lower panel relative to a building structure between the building structure and an external space, the intermediate mullion assembly comprising:

• an intermediate body defining an intermediate cavity therein in which air is isolated for at least partially thermally insulating the building structure relative to the external space;
• the intermediate body being securable to the upper and lower panels;
• and
• at least one thermal insulator element at least partially positionable between the upper and lower panels, to at least partially define at least one thermal break between the external space and the intermediate body.

A jamb mullion assembly for securing a panel in a selected position relative to a building structure between the building structure and an external space, the jamb mullion assembly comprising:

• a jamb mullion body defining a jamb mullion cavity therein in which air is isolated for at least partially thermally insulating the building structure relative to the external space;
• the panel comprising a glazing unit that is secured to the jamb mullion body and extending from a preselected side of the jamb body;
• and
• the jamb mullion body additionally comprising a closed side that is secured to the building structure.

A method of securing a first panel unit in a predetermined position relative to a building structure between the building structure and an external space, the method comprising:

• (a) engaging a first mullion segment with a substantially vertical second mullion segment, to attach the first and second mullion segments to each other to provide a mullion assembly defining a central cavity therein at least partially defined by a boundary region in which a central volume of air is isolated for thermally insulating the building structure relative to the external space and to position first and second panels associated with the first and second mullion segments respectively between the boundary region and the external space, the first and second panels comprising first and second glazing units respectively;
• (b) positioning at least one thermal insulator element between the boundary region and the external space, for thermally insulating the building structure relative to the external space;
• (c) while the first mullion segment is attached to the second mullion segment, engaging a first transverse mullion segment with a substantially horizontal second transverse mullion segment, to attach the first and second transverse mullion segments to each other to provide a transverse central region in which a transverse central volume of air is substantially isolated to at least partially insulate the building structure relative to the external space, the engaged first and second transverse mullion segments defining a separation region between the building structure and the external space;
• (d) positioning at least one transverse thermal insulator element between the separation region and the external space, for thermally insulating the building structure relative to the external space;
• and
• (e) with at least one fastener, fastening at least one cover element to the mullion assembly to engage preselected portions of each of the first and second glazing units to at least partially define said at least one thermal break between the external space and the boundary region.

A curtain wall system to be secured to a building structure located between the building structure and an external space, the curtain wall system comprising:

• a plurality of panel units attachable to each other, each said panel unit comprising:
• a first mullion segment comprising:
• an elongate first main portion extending between first top and bottom ends thereof and comprising a first exterior side thereof, the elongate first main portion extending between inner and outer ends thereof;
• a first outer portion extending from the first main portion at the outer end thereof;
• a second mullion segment comprising:
• an elongate second main portion extending between second top and bottom ends thereof and comprising a second exterior side thereof, the elongate second main portion extending between inner and outer ends thereof;
• a second outer portion extending from the second main portion at its outer end thereof;
• at least one first panel positioned between the first and second mullion segments, said at least one first panel comprising a first glazing unit secured to the first outer portion and at least partially positioned between the external space and the first outer portion;
• a first transverse mullion segment and a second transverse mullion segment, each of the first and second transverse mullion segments being secured between the first and second exterior sides of the first and second mullion segments respectively, to locate the first and second main portions spaced apart from each other by a predetermined distance;
• said at least one first panel being held between the first and second mullion segments and the first and second transverse mullion segments;
• the first mullion segment of each of the panel units being attachable to a secured second mullion segment of a first installed one of the panel units comprising at least one second panel and being installed on the building structure, to provide a mullion assembly defining a central cavity therein in which a central volume of air is isolated for at least partially thermally insulating the building structure relative to the external space, the first and secured second mullion segments, when attached together, additionally defining a boundary region between the central cavity and the external space;
• the secured second mullion segment comprising a secured second main portion extending between inner and outer ends thereof and a secured second outer portion attached to the secured second main portion at the outer end;
• said at least one second panel being secured to the second outer portion and at least partially positioned between the external space and the second outer portion;
• each said mullion assembly comprising at least one thermal insulator element at least partially positioned between said at least one first panel and said at least one second panel to at least partially define at least one thermal break between the external space and the boundary region;
• and
• said at least one thermal insulator element comprising an external engagement portion located between said at least one first panel and said at least one second panel and exposed to the external space, the external engagement portion being engaged with the first and second panels to at least partially provide said at least one thermal break between the external space and the boundary region.

A method of securing a first panel unit in a predetermined position relative to a building structure between the building structure and an external space, the method comprising:

• (a) engaging a first mullion segment with a substantially vertical second mullion segment, to attach the first and second mullion segments to each other to provide a mullion assembly defining a central cavity therein at least partially defined by a boundary region in which a central volume of air is isolated for thermally insulating the building structure relative to the external space and to position first and second panels associated with the first and second mullion segments respectively between the boundary region and the external space, the first and second panels comprising first and second glazing units respectively;
• (b) while the first mullion segment is attached to the second mullion segment, engaging a first transverse mullion segment with a substantially horizontal second transverse mullion segment, to attach the first and second transverse mullion segments to each other to provide a transverse central region in which a transverse central volume of air is substantially isolated to at least partially insulate the building structure relative to the external space, the engaged first and second transverse mullion segments defining a separation region between the building structure and the external space;
• (c) positioning at least one transverse thermal insulator element between the separation region and the external space, for thermally insulating the building structure relative to the external space;
• and
• (d) positioning at least one thermal insulator element between the boundary region and the external space so that said at least one thermal insulator element engages the first and second glazing units and is exposed to the external space, for thermally insulating the building structure relative to the external space.