Curtain Wall Insulation System with Improved Back Pan

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

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

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

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

Curtain wall structures and insulation systems may also include an interior panel, commonly referred to as a back pan, that spans the area between the mullions and transoms and serves as a vapor barrier. One example of a systemfor insulating a curtain wall structurethat includes a back panis illustrated in. As seen in, the curtain wall structureis spaced from a floor slabof the building structure (not shown) to define a perimeter void. The curtain wall structureincludes framing defined by at least first and second vertically disposed and parallel mullions,, and at least first and second horizontally disposed transoms,. In addition, the curtain wall structureincludes at least one spandrel paneland at least one vision glassconnected to the mullions,and transoms,. As seen in, a back panis attached to the interior surface of the mullions,and transoms,. The system also includes reinforcing members,that extend between the mullions,and that are attached to the back pansuch that a horizontal legof reinforcing memberis positioned 2 inches (5.08 cm) below a top surface of floor slaband a horizontal legof reinforcing memberis positioned 6 inches (15.24 cm) below the top surface of floor slab. The system also includes a curtain wall insulationthat is positioned between the spandrel paneland the back pan. The curtain wall insulationis scored to receive the horizontal legs,of reinforcing members,and is friction fit between the mullions,and transoms,and abuts against the back pan. The curtain wall insulationis secured to the back panusing cup head weld pins (not shown). As seen in, the system also includes safing insulationthat is disposed within the perimeter voidand is compression fit between the back panand the floor slab. The system also includes a smoke sealantthat is applied atop the safing insulation, as well as mullion cover insulationthat is attached to mullions,.

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

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

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

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

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

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

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

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

An embodiment of a systemfor insulating a curtain wall structurein accordance with the present disclosure is shown in. The systemis useful for insulating a curtain wall structureconnected to a building structure (not shown), as well as providing perimeter firestop protection. As one of skill in the art will appreciate, a curtain wall structureis a type of exterior wall system commonly used on buildings, such as high-rise buildings, wherein the curtain wall structuredoes not bear the load of the building structure. As seen in, the curtain wall structureis spaced from a floor slabof the building structure to define a perimeter void. The curtain wall structureincludes framing defined by at least first and second vertically disposed and parallel mullions(only one shown) and at least first and second horizontally disposed and parallel transoms, such as an upper horizontally disposed transomand a lower horizontally disposed transom. The transoms,are separated by a transom distance TD, which corresponds to the distance between a bottom surfaceof the first transomand a top surfaceof the second transom. The mullionsand transoms,are typically hollow box-shaped members formed of aluminum. As shown in, the curtain wall structurealso includes a spandrel panelconnected to the framing. The spandrel panelprovides an exterior fac̨ade of the curtain wall structureand is commonly formed of glass, aluminum, stone, thin sheets of foam material, and the like. The systemprovides thermal insulation and also provides a barrier to inhibit the spread of fire from one floor of a building to an upper adjacent floor through the perimeter void.

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

Now referring to, the back panhas an exterior facing surfaceand an interior facing surface. In addition, the back panhas an installed length Land a material length. As seen in, the installed length Lcorresponds to the linear length measured from a first endof the back panto a second endof the back pan. The material length (not labeled) corresponds to the length measured along the back panitself from the first endto the second end.

In accordance with the present disclosure, the installed length Lof the back panis greater than or equal to the transom distance TD. Thus, the installed length Lensures that the area between the transoms,is covered by the back pan. In some embodiments, the transom distance TD can be at least about 50.8 cm or more (when the floor slabis level with the bottom surfaceof the transom). In some embodiments, Tis in the range of about 52.07 cm to about 127 cm. In some embodiments, the installed length Lof the back panis 2 cm to 8 cm greater than the transom distance T. In some embodiments, the installed length Lof the back panis 5 cm to 8 cm greater than the transom distance Tso that the first and second ends,of the back panoverlap the transoms,by 2.5 cm to 4 cm.

In accordance with the present disclosure, the material length of the back panis greater than the installed length Lof the back pan. In some exemplary embodiments, the material length results from controlled deformation of a flat metal or metal alloy sheet (e.g., a sheet of galvanized steel), such as by stamping, crimping, or corrugating techniques. By having a material length that is greater than the installed length L, the strength of the back panis increased as compared to a back pan having a material length that is equal to the installed length L, given the same material composition and thickness. Accordingly, the back panof the present disclosure has sufficient strength such that it can be utilized in the systemwithout having to attach a separate reinforcing member (such as reinforcing members,required in the systemillustrated in) to support/reinforce a safing insulationthat is compression fit between the floor slaband the back pan. This in turn reduces the number of components required in the system, which can reduce labor and material costs for constructing the system. In addition, the integrity of the vapor barrier functionality of the back panis maintained by not creating penetrations through the back panwhen attaching a separate reinforcing member.

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

As seen in, in certain aspects, the back pancomprises at least one interior facing ribthat abuts at least a portion of the safing insulationand at least one exterior facing ribthat abuts at least a portion of the curtain wall insulation. In other aspects, the back panmight include only one or more interior facing rib(s)or only one or more exterior facing rib(s). As seen in, the ribs,can be formed in a variety of configurations or shapes. For example, the ribs,can be U-shaped with a curved or rounded end (as shown in) or V-shaped with a flat or planar end (as shown in). In certain aspects, and as shown in, the back panincludes exterior facing ribsthat are V-shaped. It is also contemplated that the back pancan include at least one interior facing riband at least one exterior facing ribthat have different configurations. For example, the at least one interior facing ribmay be V-shaped with a flat or planar end, while the at least one exterior facing ribis V-shaped.

With reference to, in certain aspects, the back panmay include multiple ribs,that repeat uniformly between the first and second ends,. As seen in, the back panmay have a pitch P, which describes the distance between adjacent repeating ribs, and a height H. In certain aspects, the pitch P is greater than the height H. In certain aspects, the pitch P is equal to the height H. In certain aspects, the pitch P is less than the height H.

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

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

As shown in, the systemof the present disclosure also includes a safing insulationdisposed within the perimeter voidand compression fit between the interior facing surfaceof the back panand the floor slab. The safing insulationinhibits flames and hot gases from moving from one floor to an adjacent upper floor through the perimeter void. As with the curtain wall insulation, the safing insulationmay be formed of various materials based on a desired failure temperature of the material. In certain embodiments, the safing insulationcomprises mineral wool. The safing insulationmay have a thickness of 2.54 cm to 20.32 cm and a density of 64 kg/mto 225 kg/m. Such safing insulationis commercially available from Thermafiber, Inc. (Joplin, Missouri). When installed, the safing insulationis typically compressed to varying degrees, but normally it is compressed to at least about 25% of its original thickness. After installation, the safing insulationprovides fireproof sealing of the perimeter void. Because the safing insulationis compressed when installed, it provides some capability to expand which can seal openings or cracks that might otherwise develop in the perimeter void. Slight variations in the size of the perimeter voiddue to expansion or other environmental changes are accommodated by the safing insulationsince it is compressed when placed in the perimeter void, and thus can provide an effective seal under various conditions.

In certain aspects, the systemis arranged such that a top surfaceof the safing insulationis separated from the bottom surfaceof the first transomby a vertical distance of at least 2.5 cm or more, such as at least about 7.6 cm or more. The systemmay be arranged such that a bottom surfaceof the safing insulationis substantially coplanar with the top surfaceof the second transom. The systemmay be arranged such that the bottom surfaceof the safing insulationis separated from the top surfaceof the second transomby a vertical distance of at least 2.5 cm or more (e.g., at least about 7.6 cm or more). The components of the present system, and particularly the back pan, allow arrangements where the transoms,are vertically separated from the safing insulationwithout requiring a reinforcing member, whereas conventional systems that include a back pan and no additional reinforcing member (e.g., System No. CW-D-1044) require there to be essentially no vertical separation between the top surface of the safing insulation and the bottom surface of an upper transom member. Accordingly, the systemof the present disclosure provides more design freedom as opposed to conventional systems.

In certain embodiments, and as shown in, the systemalso includes a mullion cover insulationto cover and protect a portion of the mullionfrom hot flames and gasses during a fire. As seen in, the mullion cover insulationhas opposed outer and inner surfaces,and opposed top and bottom surfaces,and is attached to the mullionsuch that the outer surfaceof the mullion cover insulationabuts at least a portion of the interior facing surfaceof the back panand the top surfaceof the mullion cover insulationabuts the bottom surfaceof the safing insulationand covers a portion of the mullion. The mullion cover insulationmay be attached to the mullionusing fasteners (e.g., screws). Although not illustrated, additional pieces of mullion cover insulation configured and installed in the same manner as the mullion cover insulation may be used to cover and protect additional mullions present in the system. The mullion cover insulationmay be formed of various materials based on a desired failure temperature of the material. In certain embodiments, the mullion cover insulationcomprises mineral wool. In certain embodiments, the mullion cover insulationcomprises mineral wool faced on an inner surface with an aluminum foil or other suitable fire resistant vapor retarder material. The mullion cover insulationmay have a thickness of 2.54 cm to 20.32 cm and a density of 64 kg/mto 225 kg/m. Such mullion cover insulationis commercially available from Thermafiber, Inc. of Joplin, Missouri.

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

Embodiments of a systemfor insulating a curtain wall structurein accordance with the present disclosure are shown in. As described herein, the systemincludes a back panhaving an exterior facing surfaceand an interior facing surface. Furthermore, the back pancomprises at least one of an interior facing ribor an exterior facing rib.

Now referring to, the back pancan have a flangeextending from a perimeter of the exterior facing surface. The flangecan extend outwardly from the back pansuch that an angle between the flangeand the exterior facing surfaceis greater than or equal to 90 degrees. The flangeincludes a perimeterdistal to the exterior facing surface. The perimeterhas a first endand a second end. The first endabuts the bottom surfaceof the first transom, the spandrel panel, or a junction thereof. The second endabuts the top surfaceof the second transom, the spandrel panel, or a junction thereof. As described herein, the back pancan interface with the framing in a variety of ways. For example, the back pancan be joined to the framing by mechanical fasteners that extend through the flangeand into the framing. As seen in, the back panhas an interior installed length of Lwhen viewing the interior facing surface; an exterior installed length of Lwhen viewing the exterior facing surface; and a material length. As seen in, the interior installed length Lcorresponds to the linear length measured from a first endof the back panto a second endof the back pan. The exterior installed length Lcorresponds to the linear length measured from the first endto the second endof the perimeterof the flangeof the back pan. In some embodiments where the back panincludes the flange, the material length (not labeled) corresponds to the length measured along the back panitself from the first endto the second end

In accordance with the present disclosure, the exterior installed length Lis approximately equal to a transom distance T. Thus, the exterior installed length Lensures that the area between the transoms,is covered by the back pan. The interior installed length Lis less than or equal to the transom distance T, thereby creating a gap between the interior facing surfaceof the back panand either or both of the transoms,. As shown in, the gap may be split into two gaps, Gand G. Gap Gis a gap between the first endof the back panand the bottom surfaceof the first transom. Gap Gis a gap between the second endof the back panand the top surfaceof the second transom. Gand Gmay be substantially equal in size. In some embodiments, at least one of the gaps Gand Gare about ½″ (about 1.27 cm) or less, about ⅜″ (about 0.95 cm) or less, about ¼″ (about 0.64 cm) or less, about 3/16″ (about 0.48 cm) or less, about ⅛″ (about 0.32 cm) or less, about 1/16″ (about 0.16 cm) or less, etc. Similarly, an interior installed width of the back panmay be less than a distance between mullions, thereby creating a gap between the interior facing surfaceof the back panand either or both of the mullions. The aforementioned gaps between the interior facing surfaceand the framing may bias the back panto expand toward an inside of the building due to heat from a fire. The inward expansion of the back panmay close the gaps. However, since the back panis already expanding in an inward direction, the back panmay continue to expand inwardly despite the gaps being closed (i.e., due to inward momentum of the back pan). By encouraging the back panto expand toward the inside of the building due to a fire, the back panapplies increased pressure to the safing insulation, thereby ensuring the safing insulation does not become dislodged from the perimeter void.

Moreover, the interior installed length Lis less than or equal to the exterior installed length L. Accordingly, the flangecan extend outwardly from the back pansuch that the angle between the flangeand the exterior facing surfaceis greater than or equal to 90 degrees.

In accordance with the present disclosure, the material length of the back panis greater than the exterior installed length L. As described herein, the material length results from controlled deformation of a flat metal or metal alloy sheet, such as by stamping, crimping, rolling, corrugating, or the like. For example, processing a sheet of galvanized steel such that the flange, the interior facing rib, the exterior facing rib, or a combination thereof is included in the back pancontributes to the material length being greater than the exterior installed length L. Similarly, a portion of the material length of the back pandisposed between the first endand the second endis greater than the interior installed length L. Including the interior facing rib, the exterior facing rib, or a combination thereof in the back pancontributes to this portion of the material length being greater than the interior installed length L.

As seen in, in certain aspects, the back pancomprises an exterior facing ribthat abuts at least a portion of a curtain wall insulation. The exterior facing ribcan be substantially triangular, as shown in. In some embodiments, the exterior facing ribmay be U-shaped or semicircular with a curved bottom or a flat bottom. The ribcan have a depth equal to or less than a thickness of the curtain wall insulation. The ribcan extend fully or partially through the thickness of the curtain wall insulation. In some embodiments, the ribcan extend into the curtain wall insulationto a depth of about 1% to about 100% of the thickness of the curtain wall insulation. For example, the ribcan extend into the curtain wall insulationto a depth of about 5% to about 50% of the thickness of the curtain wall insulation. The ribcan have a depth or a radius equal to or less than about 2″ (about 5.08 cm), such as about 1″ (about 2.54 cm), about ½″ (about 1.27 cm), etc. The ribhas a height measured from a lower end of the rib (i.e., a portion of the rib that is closer to the lower endof the back pan) to an upper end of the rib (i.e., a portion of the rib that is closer to the upper endof the back pan). As shown in, in certain aspects, the height of the ribcan be equal to or approximately (+/−10%) the same as a height S of the safing insulationmeasured from the bottom surfaceto the top surfaceof the safing insulation. The height of the ribensures that the safing insulationnaturally fills the (triangular) cavity formed by the ribwithout requiring excess further compressive force that might otherwise cause the safing insulationto not fill the cavity, thereby maximizing fireproofing effectiveness. The ribcan be formed on the back pansuch that the ribis at least partially in line with the floor slab. For example, the ribis at least partially disposed between a first horizontal plane coplanar with a top surface of the floor slaband a second horizontal plane coplanar with a bottom surface of the floor slab. Further, the ribcan be formed on the back pansuch that the ribis at least partially disposed between a third horizontal plane coplanar with the top surfaceof the safing insulation and a fourth horizontal plane coplanar with the bottom surfaceof the safing insulation. In other words, the ribis at least partially in line with the safing insulation(i.e., the ribis at least partially in the same horizontal plane as the safing insulation). Furthermore, the ribcan be formed on the back pansuch that the ribis at least partially disposed above a fifth horizontal plane that is midway between the third horizontal plane and the fourth horizontal plane. In other words, the fifth horizontal plane is positioned at about% of a height of the safing insulation. Moreover, the ribcan be formed on the back pansuch that the ribis at least partially disposed below a sixth horizontal plane that is midway between the third horizontal plane and the fifth horizontal plane. In other words, the sixth horizontal plane is positioned at about 75% of a height of the safing insulation. It is contemplated that the ribcan be positioned at least partially above the top surfaceof the safing insulation. It is further contemplated that the ribcan be positioned at least partially below the bottom surfaceof the safing insulation.

In certain embodiments, and as shown in, interior facing ribcan support the safing. For example, the ribmay prevent the safingfrom being installed too deeply in the perimeter void(e.g., the top surfaceof the safingis sub-flush with a top surface of the floor slab). The interior facing ribcan be substantially triangular or V-shaped, as shown in. Further, the ribmay have a truncated point. The ribcan have a depth equal to or less than a thickness of the mullion cover insulation. The ribcan extend fully or partially through a thickness of the mullion cover insulation. In some embodiments, the ribcan extend into the mullion cover insulationto a depth of about 1% to about 100% of the thickness of the mullion cover insulation. For example, the ribcan extend into the mullion cover insulationto a depth of about 5% to about 50% of the thickness of the mullion cover insulation. The ribcan have a depth equal to or less than about 2″ (about 5.08 cm), such as about 1″ (about 2.54 cm).

Moreover, the ribcan be formed on the back pansuch that the ribis at least partially in line with the floor slab. For example, the ribis at least partially disposed between the first horizontal plane coplanar with a top surface of the floor slaband the second horizontal plane coplanar with a bottom surface of the floor slab. Further, the ribcan be formed on the back pansuch that the ribis at least partially disposed between the third horizontal plane coplanar with the top surfaceof the safing insulation and the fourth horizontal plane coplanar with the bottom surfaceof the safing insulation. In other words, the ribmay be at least partially in line with the safing insulation(i.e., the ribis at least partially in the same horizontal plane as the safing insulation). Furthermore, the ribcan be formed on the back pansuch that the ribis at least partially disposed above the fifth horizontal plane that is midway between the third horizontal plane and the fourth horizontal plane. Moreover, the ribcan be formed on the back pansuch that the ribis at least partially disposed below the sixth horizontal plane that is midway between the third horizontal plane and the fifth horizontal plane. It is contemplated that the ribcan be positioned at least partially above the top surfaceof the safing insulation. It is further contemplated that the ribcan be positioned at least partially below the bottom surfaceof the safing insulation.

Moreover, the riborcan include an upper portion and a lower portion. For example, as shown in, the ribcan be positioned such that the lower portion of the ribis disposed vertically above the bottom surfaceof the safing insulation. As shown in, the ribcan be positioned such that the upper portion of the ribabuts the bottom surfaceof the safing insulation. Further, the ribcan include the lower portion such that the lower portion abuts the top surfaceof the mullion cover insulation. Furthermore, a top end of the mullion cover insulationmay include a relief shape. The relief shapecorresponds to a shape of the ribsuch that the mullion cover insulationmay be installed over the back panwithout the ribcreating a bulge, such as a bulge on the inner surfaceof the mullion cover insulation. Furthermore, the upper portion and the lower portion can converge to form an angle θ of the ribor. For example, as shown in, the upper portion and the lower portion of the ribcan form an angle θ, where θ is less than 90°. In some embodiments, θ can be about 80° or less, about 60° or less, about 45° or less, about 30° or less, etc. As shown in, θ can be in the range of about 75° to about 80°, such as about 76° or about 77.5°. As shown inθ can be about 30°.

As seen in, ribs,can be formed in a variety of configurations, shapes, or directions. For example, the ribs,can be U-shaped with a curved or rounded end, as shown in; rectangular-shaped, as shown by ribin; or triangular or V-shaped, as shown by ribinandand ribin. Similar to sizes of U-shaped ribs and V-shaped ribs as described herein with reference to, a rectangular-shaped ribcan have a depth equal to or less than a thickness of the curtain wall insulation. The ribcan extend fully or partially through the thickness of the curtain wall insulation. In some embodiments, the ribcan extend into the curtain wall insulationto a depth of about 1% to about 100% of the thickness of the curtain wall insulation. For example, the ribcan extend into the curtain wall insulationto a depth of about 5% to about 50% of the thickness of the curtain wall insulation. The ribcan have a depth equal to or less than about 1″ (about 2.54 cm), such as about ½″ (about 1.27 cm). Similarly, a rectangular-shaped ribcan have a depth equal to or less than a thickness of the mullion cover insulation. The ribcan extend fully or partially through a thickness of the mullion cover insulation. In some embodiments, the ribcan extend into the mullion cover insulationto a depth of about 1% to about 100% of the thickness of the mullion cover insulation. For example, the ribcan extend into the mullion cover insulationto a depth of about 5% to about 50% of the thickness of the mullion cover insulation. The ribcan have a depth equal to or less than about 1″ (about 2.54 cm), such as about ½″ (about 1.27 cm). The riborhas a height measured from a lower end of the rib (i.e., a portion of the rib that is closer to the lower endor the back pan) to an upper end of the rib (i.e., a portion of the rib that is closer to the upper endof the back pan). The height can be equal to or less than a height S of the safing insulationmeasured from the bottom surfaceup to the top surfaceof the safing insulation. The ribcan have a height such that at least a portion of an end of the safingcan be disposed within a void formed by the rib. The riborcan have a height of about 8″ (about 20.3 cm) or less, such as about 4.5″ (about 11.4 cm) or less, about 4″ (about 10.2 cm) or less, about 1″ (about 2.54 cm) or less, etc. The riborcan have a height of about ½″ (about 1.27 cm) or greater, such as about 1″ (about 2.54 cm) or greater, 4″ (about 10.2 cm) or greater, about 4.5″ (about 11.4 cm) or greater, etc. In some embodiments, the riborcan have a height in the range of about 4″ to about 4.5″.

As described herein, the ribs,can be formed on the back pansuch that the riboris at least partially disposed between the top surfaceand the bottom surfaceof the safing insulation. With reference to, in certain aspects, the back panmay include ribdisposed at least partially above a first height S which corresponds to about 50% of the height S of the safing insulation. In other words, at least a portion of the ribis positioned above a midpoint between the bottom surfaceand the top surfaceof the safing insulation. Further, the back panmay include the ribdisposed at least partially below a second height Swhich corresponds to about 75% of the height S of the safing insulation. In other words, at least a portion of the ribis positioned below a point that is located midway between the aforementioned midpoint and the top surfaceof the safing insulation.

In certain embodiments, and as shown in, the safingcan include a relief shape. The relief shapecorresponds to a shape of an interior facing rib. Accordingly, the safingmay be more accurately positioned within the perimeter voidwithout the ribcreating a bulge, such as a bulge on the top surfaceof the safing. Further, in certain embodiments, and as shown in, the safingcan include a ramped section. The ramped sectionmay have a depth into the safing insulation approximately equal to a depth of the rib. Accordingly, ease of installing the safingmay be improved by ramping up the force required to friction fit the safinginto the perimeter voidas the safingis increasingly compressed by the ribas the ribtravels along the ramped section.

With reference to, in certain aspects, the back panincludes at least one of an interior facing ribor an exterior facing rib, where the ribormay extend fully or partially across a width of the back pan. As seen in, in certain aspects, the back panincludes ribextending fully across the width of the back pan. For example, the ribextends through the flangeon one or both ends of the back pan. As seen in, in certain aspects, the back panincludes ribextending partially across the width of the back pan. For example, the ribextends across a majority of the width of the back pan, however, there is a distance D from an end of the ribto a widthwise end of the back pan(e.g., a vertical edge of the back panat an intersection of the interior facing surfaceand the flange). Furthermore, as seen in, one or more ribs can be positioned on the back pansuch that the back panis symmetrical across a central vertical axis Y-Y and/or a central horizontal axis X-X. For example, the distance D may be substantially equal from each end of the ribto a vertical edge of the back pansuch that the back panis symmetrical across axis Y-Y. In such an embodiment, the back panmay have similar resistance to warping across a width of the back pan.

As shown in, the ribis triangular-shaped and extends into a depth of the back pan. While the ribcan extend to any practical depth, in certain embodiments, the ribextends to 50% or less of the depth of the back pan. In some embodiments, the ribextends to a depth of 20% to 40% of the thickness of the back pan. In certain embodiments, the ribextends to a depth of about 33% of the thickness of the back pan. For example, if the back panis about 7.62 cm thick, the ribwould extend about 2.54 cm into the back pan. The ribis situated between the first endand the second endof the back pan. In the exemplary embodiment shown in., the ribis situated closer to the first endthan the second end. In, an upper portion of the ribis substantially flush with the interior facing surfaceof the back pan and slopes (at an angle θ) into the back panto reach the aforementioned depth (e.g., of about 2.54 cm or ⅓ the thickness of the back pan). Here, θ is in the range of about 75 degrees to about 79 degrees, such as about 77 degrees. In this manner, the lower portion of the ribis a substantially flat 2.54 cm “shelf” formed in the back pan.

As seen in, in certain aspects, the back panincludes the riband a second rib, where the ribs,are substantially equally spaced from the central horizontal axis X-X that is disposed midway between the first endand the second end. In other words, ribs can be formed on the back pansuch that the back panis symmetrical along a horizontal axis. In such an embodiment, the back panmay be installed such that the first endis an upper end of the back panor such that the second endis an upper end of the back panwithout degrading the ability of the back panto resist warping when exposed to heat, such as heat from a fire.

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

As seen in, the insulated curtain wall componentincludes framing defined by at least first and second vertically disposed and parallel mullions,and at least first and second horizontally disposed and parallel transoms, such as an upper horizontally disposed transomand a lower horizontally disposed transom. The transoms,are separated by a transom distance T, which corresponds to the distance between a bottom surfaceof the first transomand a top surfaceof the second transom, as illustrated in. The mullions,and transoms,are typically hollow box-shaped members formed of aluminum. As shown in, the insulated curtain wall componentmay also include a spandrel panelconnected to the framing. The spandrel panelprovides an exterior fac̨ade and is commonly formed of glass, aluminum, stone, thin sheets of foam material, and the like.

With continued reference to, the insulated curtain wall componentincludes a back paninterfaced with the framing. The back pancan interface with the framing in a variety of ways. For example, the back pancan be interfaced with, or otherwise joined to, the framing by mechanical fasteners (e.g., screws), by welding, or other techniques known to those of skill in the art. The back panmay be formed of a metal or a metal alloy, although other materials that function as a vapor barrier and are otherwise suitable for use in unitized curtain wall system applications may be used. In certain embodiments, the back pancomprises galvanized steel. In certain embodiments, the back pancomprises galvanized steel having a gauge ofto. In certain embodiments, the back pancomprises galvanized steel having a gauge ofto.

As seen in, the back panhas an exterior facing surfaceand an interior facing surface. In addition, the back panhas an installed length Land a material length. As seen in, the installed length Lcorresponds to the linear length measured from a first endof the back panto a second endof the back pan. The material length corresponds to the length measured along the back panitself from the first endto the second end.

In accordance with the present disclosure, the installed length Lof the back panis greater than or equal to the transom distance T. Thus, the installed length Lensures that the area between the transoms,is covered by the back pan, as illustrated in. In certain embodiments, the installed length Lof the back panis 2 cm to 8 cm greater than the transom distance T. In certain embodiments, the installed length Lof the back panis 5 cm to 8 cm greater than the transom distance Tso that the first and second ends,of the back panoverlap the transoms,by 2.5 cm to 4 cm. Moreover, similar to a back panhaving a flangeas shown in, the back pan(e.g., in an embodiment where the back panincludes a flange) can have an exterior installed length approximately equal to the transom distance TD. Thus, the exterior installed length of the back panensures that the area between the transoms,is covered by the back pan. Furthermore, similar to the back panshown in, the back pancan have an interior installed length that is less than or equal to the transom distance T, thereby creating a gap between the interior facing surfaceof the back panand either or both of the transoms,. Similarly, an interior installed width of the back panmay be less than a distance between mullions, thereby creating a gap between the interior facing surfaceof the back panand either or both of the mullions.

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

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

As seen well in, in certain aspects, the back pancomprises an interior facing ribconfigured to abut at least a portion of a safing insulation of a perimeter fire containment system. In certain aspects, the back pancomprises an exterior facing ribthat abuts at least a portion of a curtain wall insulationof the insulated curtain wall component. In certain aspects, the back pancomprises at least one interior facing riband at least one exterior facing rib. The back panof the insulated curtain wall componentcan be formed in a variety of configurations or shapes, including the shapes and configurations previously described with respect to.