Abstract:
A window frame including a pair of frame halves having integral fasteners for interconnecting the frame halves. The fasteners include integral cooperating alignment pins and receivers for aligning the fasteners and hence the frame halves.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention relates to window frames and more particularly to window frames that can be installed without screws or fasteners.  
           [0002]    Window frames, such as those used in doorlights, are well known. Doorlight frames in particular, usually include two frame halves—one interior and one exterior—that are screwed together or otherwise interconnected. The frame halves are positioned on opposite sides of an object, such as a door, to support a glazing panel, such as insulated glass. Illustrative doorlight frames are illustrated in U.S. Pat. No. 5,644,881 issued Jul. 8, 1997 to Neilly; U.S. Pat. No. 5,133,168 issued Jul. 28, 1992 to Neilly et al; U.S. Pat. No. 4,920,718 issued May 1, 1990 to Artwick et al; and U.S. Pat. No. 4,021,967 issued May 10, 1977 to Mulder et al. Although these frames enjoy widespread popularity, they can be relatively time consuming to install. Additionally, the screws used to install the frames, as well as the accompanying screw holes, are unsightly after installation of the frame.  
           [0003]    Some “screwless” doorlight frames have been developed in an attempt to solve these problems. An example is illustrated in U.S. patent application Ser. No. 09/412,763 filed Oct. 1, 1999 by Gerard. The Gerard construction includes two interconnecting systems—one for temporarily connecting the two halves and one for permanently connecting the two halves. Neither interconnecting system is visible from the exterior side of the frame.  
           [0004]    Unfortunately, this Gerard frame, as well as similar screwless window frames, is not without its problems. One significant problem with the Gerard construction is that it can be difficult to properly align the two frame halves when attempting to permanently secure them. This increases the time necessary to install the frames. Additionally, with this construction it is possible to intersecure the frames out of alignment. Once the frame halves are interlocked it is extremely difficult to separate and reposition the frame halves, thus the consumer generally has the options of using the misaligned frame or installing a new system. The first option is aesthetically unpleasing and can reduce the life of the doorlight by allowing dust and debris into the frame from the misaligned portions. The latter option is both costly and time consuming.  
         SUMMARY OF THE INVENTION  
         [0005]    The aforementioned problems are overcome by the present invention wherein a window frame includes an integral fastening system and an integral alignment system. The frame halves can easily be properly aligned and intersecured during the installation of a doorlight in a door. Preferably, the interconnecting system includes the alignment system.  
           [0006]    As disclosed, the frame halves include mating barbed connectors that interfit with one another to permanently intersecure the frame halves. As further disclosed, each pair of connectors includes a male connector half and a female connector half.  
           [0007]    In a further preferred embodiment, each pair of interlocking connectors includes a positioner and a positioner guide. The positioner rides along the positioner guide during installation to ensure proper alignment of the female connector half and male connector half.  
           [0008]    The present invention provides a simple and effective window frame that is easily and securely aligned and interconnected. The connectors include positioning structures to ensure proper alignment of the frame halves.  
           [0009]    These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the Detailed Description of the Preferred Embodiment and the drawings.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    [0010]FIG. 1 is a perspective exploded view of a doorlight incorporating the window frame of the present invention;  
         [0011]    [0011]FIG. 2 is an interior plan view of the first frame half;  
         [0012]    [0012]FIG. 3 is a side elevational view of the first frame half;  
         [0013]    [0013]FIG. 4 is a side elevational view of a male piece of the first frame half;  
         [0014]    [0014]FIG. 5 is a cross-sectional view of the male piece taken along line V-V;  
         [0015]    [0015]FIG. 6 is a side elevational view of a female piece of the first frame half;  
         [0016]    [0016]FIG. 7 is a cross-sectional view of the female piece taken along line VII-VII;  
         [0017]    [0017]FIG. 8 is an end elevational view of the assembled frame; and  
         [0018]    [0018]FIG. 9 is a cross-sectional view taken along line IX-IX of FIG. 8. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0019]    A doorlight constructed in accordance with a preferred embodiment of the invention is illustrated in the drawings and generally designated  10 . With reference to FIG. 1, the doorlight includes an insulated glass assembly  12 , a first frame half  14  and a second frame half  16 . The first and second frame halves  14 ,  16  have an interconnecting system including male pieces  20  and female pieces  22  (see FIGS. 4 and 5). These components securely connect the first and second frame halves  14 ,  16  when the first and second frame halves  14 ,  16  are pushed together to install them in a door. Each frame half includes gaskets  24  installed along gasket tracks  26 . The gaskets  24  seal the glass assembly  12  between the first and second frame halves  14 ,  16  and seal the first and second frame halves  14 ,  16  to the door. Though the window frame assembly will be described with reference to a door and doorlight, it is to be understood that the present invention is suitable for use in a variety of settings, such as installation of windows in walls.  
         [0020]    The present invention will now be described in greater detail with reference to FIGS.  2 - 7 . The first frame half  14  and second frame half  16  are generally identical to one another and together comprise a single window frame. Because the two frame halves are identical, only the first frame half  14  will be described in detail.  
         [0021]    The first frame half  14  is generally a single integral piece injection molded of high strength plastic. Preferably, the plastic is stainable and/or paintable such as the frames sold by ODL, Incorporated of Zeeland, Michigan under the trademark HP PRO™. Other materials suitable for construction of the frame halves are well known to those skilled in the art.  
         [0022]    The first frame half  14  includes an external surface  30  which provides a molding appearance. Appropriate shapes for the external surface  30  are known to those skilled in the art Often, the surface is configured and/or textured to simulate the appearance of wood molding.  
         [0023]    The first frame half  14  includes a door engagement portion  32  and a glass engagement portion  34 . Each door engagement portion  32  and glass engagement portion  34  defines a gasket track  26  facing the door D or glass  12 , respectively. The gasket track  26  is a substantially U-shaped channel running the length of each side of the first frame half  14 . Though the invention will be described in relation to a U-shaped gasket track, the gasket track  26  may be any other shape, such as semicircular, as desired.  
         [0024]    A gasket  24  is attached along the length of the gasket track  26 . If the novel gasket track and gasket are not used, a caulk or other sealant may be applied along the door engagement portion  32  and glass engagement portion  34  to enhance sealing against the respective components.  
         [0025]    The underside  36  of the first frame half  14  is perhaps best illustrated in FIG. 2. This side of the frame includes a pair of integrally molded reinforcing longitudinal ribs  38  and  40 , which extend around the entire perimeter of the first frame half  14 . Lateral or transverse ribs  42  are optionally spaced around the perimeter of the first frame half  14  and are perpendicular to the longitudinal ribs  38  and  40 . All of the ribs provide enhanced structural integrity for the first frame half  14 , and they also support the other frame components discussed below. Because the first frame half  14  is a single injection molded component, the ribs  38 ,  40 ,  42  are integral with the frame and with one another.  
         [0026]    The interconnecting system consists of male pieces  20  and female pieces  22 . As can be seen in FIG. 2, a small distance from either side of each male piece the longitudinal ribs  38 ,  40  join so that a single rib  39  projects from both sides of each male piece  20 . Each male piece  20  projects upwardly from a single rib  39 .  
         [0027]    The male pieces  20 , which can perhaps be best understood with reference to FIGS. 4 and 5, consist of a positioner  50 , a stem  52  and a number of barbs  54 . Each male piece  20  is preferably molded as an integral piece, and is more preferably integrally molded with the frame half to which it is attached. The stem  52  is a rectangular tab having a first end  56  and a second end  58 . The first end  56  is connected to the first frame half  14  so that the stem  52  projects outwardly from the first frame half  14 . The stem  52  is preferably connected to the first frame half  14  so that the stem  52  is centered between the door engagement portion  32  and the glass engagement portion  34 . The second end  58  of the stem  52  is rounded to facilitate insertion of the male piece  20  into the female piece  22 , as will be discussed in further detail below.  
         [0028]    The barbs  54  are substantially triangular, each barb having a base  60  and a tip  62 . The barbs  54  protrude from the sides of the stem  52  so that the base  60  slopes slightly downward from the stem  52 , the base  60  of each barb  54  forming an acute angle with the stem  52 . The barbs  54  are stacked on both sides of the stem  52  so that the tip  62  of each barb  54  contacts the base  60  of the next higher barb  54  in the stack. There are preferably three barbs  54  stacked on the door engagement side of the stem  52  and one barb  54  on the glass engagement side of the stem  52 .  
         [0029]    The positioner  50  is a substantially rectangular tab having a width  51  and a depth  53 . The positioner  50  is attached to one end of the stem  52 . In a preferred embodiment, the positioner  50  is slightly taller than the stem  52  so that an end  64  of the positioner  50  extends beyond the height of the stem  52 . The end  64  of the positioner  50  is rounded to facilitate insertion of the male piece  20  into the female piece  22 . The width  51  of the positioner  50  preferably is such that the edges of the positioner  50  extend beyond the sides of the stem  52  but do not extend beyond the bases  60  of the barbs  54 , as can be seen in FIG. 5.  
         [0030]    As can perhaps be best seen in FIGS. 6 and 7, each female piece  22  consists of a first wall  70 , a second wall  72 , a number of teeth  74  and two positioner guides  76 . Each female piece  22  is preferably molded as an integral piece, and is more preferably integrally molded with the frame half to which it is attached. Each of the first wall  70  and second wall  72  has an inner surface  78  and two side edges  79  and a top edge  81 . Each wall is attached to a longitudinal rib  38 ,  40  so that the inner surface  78  of the first wall  70  faces the inner surface of the second wall  72 . The height of the first wall  70  and second wall  72  is at least the height of the positioner  50 .  
         [0031]    A number of triangular teeth  74  project inwardly from the inner surface  78  of each wall. Each tooth  74  has a base  80  and a tip  82 . The teeth  74  protrude from the inner surface  78  of each wall so that the base  80  slopes slightly downward respective to the wall from which it protrudes, the base  80  of each tooth  74  forming an acute angle with the wall. The teeth  74  are stacked on the inner surface  78  of both the first wall  70  and the second wall  72  so that the tip  82  of each tooth  74  contacts the base  80  of the next higher tooth  74  in the stack. In a preferred embodiment, three teeth  74  are stacked on each of the first wall  70  and the second wall  72 . The tip  82  of the top tooth  74  in each stack preferably contacts the top edge  81  of the respective wall. In an alternative embodiment, the top tooth  74  in the stack on one of the first wall  70  or second wall  72  extends slightly beyond the top of the respective wall. In this embodiment, a ramp  75  exists on the portion of the tooth  74  that extends beyond the wall. The ramp  75  is a section of the outer surface of the tooth  74  that is inclined toward the section of the tooth  74  that projects beyond the top of the wall. The ramp  75  is located on the top tooth  74  such that when the frames are installed, the ramp  75  contacts the insulated glass assembly  12 . Optionally, the upper portion of each wall (the portion including teeth  74 ) is thinner than the lower portion of each wall (the portion without teeth  74 .)  
         [0032]    The teeth  74  preferably are centered on each wall  70 ,  72 . The distance between the edge of each tooth  74  and the respective side edge  79  is at least equal to the depth  53  of the positioner  50  so that a positioner guide  76  is defined along each edge of the female piece  22 . The positioner guide  76  is a channel that runs the height of the female piece  22  the depth of which is at least the depth  53  of the positioner  50 .  
         [0033]    The male pieces  20  and female pieces  22  are spaced about each of the first frame half  14  and second frame half  16  so that, when the first frame half  14  and second frame half  16  are positioned opposite each other during installation, every male piece  20  is aligned with a female piece  22 .  
       Assembly and Use  
       [0034]    The first frame half  14  and second frame half  16  are injection molded using known techniques. The insulated glass  12  also is fabricated using known techniques and, as is obvious to those skilled in the art, includes two panes and a spacer. The first frame half  14  is positioned over a support surface. If used, the gasket  24  is applied along all gasket tracks  26  of the first frame half  14 . The insulated glass assembly  12  and door D are laid over the first frame half  14  so as to engage the glass engagement portion  34  and door engagement portion  32 , respectively. The gaskets  24  are compressed somewhat at this point due to the pressure placed on the gaskets  24  by the door D and insulated glass assembly  12 .  
         [0035]    The second frame half  16  is then laid flat and, if used, the gasket  24  is applied along all gasket tracks  26  of the second frame half  16 . The second frame half  16  is laid over the door D and insulated glass assembly  12  so that the door engagement portion  32  and glass engagement portion  34  of the second frame half contact the door D and insulated glass assembly  12 , respectively.  
         [0036]    The second frame half  16  is forced down onto the first frame half  14 . This can be done by any conventional method, such as by hand or using a rubber mallet. The gaskets  24  on the first frame half  14  and second frame half  16  are compressed where necessary when pressure is applied to the second frame half  16 . The degree to which the gaskets  24  are compressed will vary depending on the dimensions of the door D and insulated glass assembly  12 . Because the gaskets  24  will compress to accommodate the door D and insulated glass assembly  12  and will seal any gap that exists between the first and second frame halves  14 ,  16  and those components, the gaskets allow the window frame  10  to be used with doors and windows of various dimensions.  
         [0037]    As the frame halves  14 ,  16  move together, each positioner  50  aligns with and is accepted by a positioner guide  76 . The interaction of the positioner  50  and positioner guide  76  appropriately aligns the male pieces  20  and the female pieces  22  so that the stem  52  and barbs  54  of the male pieces will enter the walls  70 ,  72  of the female pieces  22  at the section of the walls  70 ,  72  having teeth  74 . As the second frame half  16  is pressed onto the first frame half  14 , the barbs  54  interlock with the teeth  74  as shown in FIGS. 8 and 9 to essentially permanently secure the first frame half  14  to the second frame half  16 . The ramp  75  rides along the pane furthest from the ribs  38 ,  40  to which the female piece  22  is attached. This guides the female piece  22  past the pane of the insulated glass assembly  12 . The intersecurement of the first frame half  14  and second frame half  16  maintains the insulated glass assembly  12  in position with respect to the door D.  
         [0038]    The above description is that of a preferred embodiment of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.