Abstract:
The present invention corrects sash sag in casement windows by implementing an adjustable hinge. The adjustable hinge includes a sash arm, a support arm, a retaining clip and an adjustment mechanism. The adjustment mechanism serves a twofold purpose. First, it allows one to adjust the hinge for sash sag, and it also secures the support arm to the track of the adjustment hinge. The adjustment mechanism includes a threaded support post and a threaded member. The threaded support post has a circumferential groove which is used to receive the arms of a retaining clip. The sash arm is mounted to the track of the adjustable hinge via a shoe block. The sash arm has a protrusion located on its bottom surface. The protrusion serves as a movement restrictor.

Description:
FIELD OF INVENTION  
       [0001]    The present invention relates to an adjustable casement window sash, and in particular to a track and hinge assembly, that compensates sash sag, by an adjustment screw. 
       BACKGROUND OF THE INVENTION  
       [0002]    Generally, casement window sashes are mounted to the window frame by hinges. These hinges may be attached either to the bottom of the window sash, or to the top of the window sash. Conversely, the hinges may be attached to both. It is typical for such a hinge to have a track mountable to the window frame. The sash arm is generally pivotally connected to a mounting shoe block, which is supported and guided, for movement lengthwise across the track. Window hinges of this type are shown, for example, in Tacheny et al. U.S. Pat. No. 4,726,093, and Sandberg et al. U.S. Pat. No. 32,846. In normal operation when the user wishes to open a casement window, let&#39;s say, for ventilation purposes or cleaning, the user will turn a crank handle in a clockwise motion, for opening the casement window, and in a counterclockwise motion, for closing the casement window. After repeated opening and closing of a casement window, the window may eventually move out of a squared position, which in turn may prevent the window sash from fully closing, thus preventing the keeper, in the casement window frame, from engaging the latch; this can be burdensome to the user. So then, why do crank-out windows become hard to close after a few years? The answer is what is known in the window industry as “sash sag”. Sash sag has been stated as “the single most asked question concerning the operating casement window today”, but as research has shown there is no simple, clear cut solution to the problem. For purposes of definition, we define the problem of sash sag as the movement of the sash relative to the window frame. The first step toward gaining an understanding of sash sag is to identify the causes. One possible cause of sash sag is something that is referred to as “sash drag”, whereby the sash will drag across the frame or sill as the window is opening or closing. Usually this problem is due to the bottom corner of the latch side of the sash dragging against the frame. 
         [0003]    There are many reasons why the sash of a casement window may begin to drag against the window frame: the sash may sag out-of-square because of improper hinge positioning, improper glazing, and poor track attachment by the manufacture, or the frame may settle out of square because of poor installation. 
         [0004]    Glazing compounds used by the manufacturers have been observed to take a considerable period of time to set up. During this time it is possible and likely for the sash to sag around the glass thereby possibly moving the sash out of square. Another cause of sash sag attributed to the manufacture is hinge positioning. This is the relationship of the top hinge to the bottom hinge and the side jamb; hinge positioning is critical in window manufacturing. Because of certain manufacturing tolerances in each hinge, there can be as much as 0.019″ lateral movement of the arm assembly within the track, which will accelerate the effects of sash sag in most residential casement windows. Yet another manufacturing defect that will further accelerate sash sag is the improper fastening of the track screws. If the track screws are not driven down as straight as possible, then the track will twist over time, and cause the sash to sag. In addition, there are some types of hinges that have track protrusions which are designed to sink into soft frame materials such as wood. However, sometimes these track protrusions do not fully sink in when the screws are tightened. This condition may allow the track to shift or rotate and contribute to the sash sag. There are some tracks that have a special flat bottom hinge track, as in the present invention, specifically designed for mounting on hard frame materials. 
         [0005]    Improper installation of the casement window is the second leading cause of sash sag, regardless of whether a frame leaves the manufacturer without any defects, and is in a square configuration or not, it must be placed into the roughed out opening and secured as squarely as possible. Any deviation from a square frame can result in apparent sash sag. In addition, casement windows which are square (shape) or wider than they are tall compound sash sag problems due to added cantilevered weight. Some experts recommend that when designing and/or specifying a casement window, the sash width should be limited to 66% of the sash height. Once again, any length discrepancies in sash or frame parts will result in the sash or frame being out of square. 
         [0006]    Sash sag is a potential problem that requires close control at all levels of the window industry. This control must be exhibited with those who manufacture component parts as well as those who assemble, transport and ultimately install window units. Each item listed above helps add to the compounding of the sash sag problem and it is possible for one or any combination of the above problems to exist! 
         [0007]    The earlier methods of correcting the problem of sash sag usually required that the hinge track be provided with slotted holes and that the hinge mounting screws in the slotted holes were to be removed to allow for shifting of the track. Repeated removal of such screws can, however, over the life of a window result in gradual loosening and depleted integrity of the window. In more recent times, sash sag has been corrected with the use of an adjustable hinge. One such type of adjustable hinge that has been employed is that of U.S. Pat. No. 5,152,102 and U.S. Pat. No. 5,074,075, issued to LaSee. In that prior art the inventor implemented an octagonal cam mechanism, so as to allow for sash sag compensation. More recently, U.S. Pat. No. 5,307,539, issued to Bauman, utilized an eccentric shaped adjustable stud, having a flange with surfaces for engaging an adjustment tool, having a pivot portion, about which the swivel arm pivots, and an eccentric neck, frictionally secured to the window frame or the track, about which the pivot axis rotates when the alignment is adjusted. However, this prior art required the user to engage a wrench, the adjustment tool, roughly perpendicular to the hinge axis. Because of the tight spaces associated with casement window hardware, this type of adjustment method can be unduly burdensome to the user. This stud type adjustment was improved upon in U.S. Pat. No. 5,964,011, assigned to Newell, by having the tool access position, in which the tool is engageable with the engagement stud, roughly parallel to the pivot axis. However, this type of configuration is unnecessarily complex with a multitude of different members, which may amount to possible malfunctions of the different members, and an added cost to production. In the present invention, the hinge may be adjusted simply, with the twist of screwdriver, or the simple twist of a finger. This is because of the simplified adjustment post, which consists mainly of a threaded screw and a threaded aperture. 
       OBJECTS OF INVENTION  
       [0008]    It is an object of the invention to provide a casement hinge which may be easily and precisely installed. 
         [0009]    It is another object of the invention to provide a casement hinge which will remain securely mounted and thereby minimize any loosening of the hinge over the life of the window. 
         [0010]    It is still another object of the invention to provide a casement hinge which may be easily adjusted over the life of the window to ensure that a tight seal be provided when the window is closed and that the window be easily and smoothly operated at all times. 
         [0011]    It is still a further object of this invention to provide a conventional casement sash unit with a screw mechanism, which is adjustable for correcting sash sag during and after installation of the casement window. 
       SUMMARY OF INVENTION  
       [0012]    The present invention is deigned to compensate for sash sag in casement windows. The typical casement window has a window sash hinged to the window frame. The hinge is generally pivotally connected to a shoe block. This pivotal connection allows the window operator the ability to open and close the window sash. As in most casement windows, after repeated use the window sash may begin to sag, “sash sag”. Conversely, a manufacturing defect, such as those listed above, may also cause the sash to sag. In order to correct the quandary of sash sag, previous casement windows required the relocation of the hinge tracks. However, this caused premature wear of the pivot mount and the pivot mounting hardware, thereby reducing the useable life of the casement window. 
         [0013]    The present invention relates to an adjustable pivotally linked hinge and track system for casement windows. The hinge has a sash arm pivotally connected, via a rivet, to a shoe block, which allows for movement across the horizontal plane of a window track. The sash arm is also pivotally connected to a support arm, via another rivet. The support arm has a bored cavity used to house the adjustment mechanism. Moreover, the support arm has a slidable flexible clip that traverses across the top surface of the support arm. In addition, if needed, the support arm has a slit or groove that gives the user additional leverage when disengaging the flexible clip. 
         [0014]    The present invention also relates to an adjustment mechanism, which includes a threaded adjustment screw having a first end constructed to receive the tip of a Philips head screwdriver, and a threaded support post capable of receiving the threaded adjustment screw. A circumferential groove is located near the top end of the threaded support post, which is capable of engaging the two opposing flexible arms of the retaining clip. 
         [0015]    The present invention further relates to a track assembly that is mounted to a window frame. A track assembly having at least one generally circular aperture for receiving the support post of the adjustment mechanism. A track assembly having a perpendicular rear end portion that has an upper arcuate lip portion. 
     
    
     
       BRIEF DESCRIPTION OF INVENTION  
         [0016]      FIG. 1  is a perspective view of the window hinge of the present invention. 
           [0017]      FIG. 2  is an exploded view of the adjustment mechanism of the present invention. 
           [0018]      FIG. 3  is a bottom view of the sash arm of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0019]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. 
         [0020]    Referring now to the drawings, and, more specifically, to  FIG. 1 , sash arm  11  is used to connect casement window  10 , not shown, to window sash  12 , not shown. Casement window  10  is used to facilitate the opening and closing of a window sash  12 . Sash arm  11  is at one end pivotally attached to shoe block  13  and is mounted along its length to the underside of window sash  12 , with a fastener, any type of fastener known in the art, but not limited to a screw, nail, tack, etc. In the present embodiment a wood screw was the preferred fastener. Sash arm  11 , as mentioned previously, is connected to shoe block  13  on one end by a suitable rivet  14 , or the like, for pivotal connection therebetween. Rivet  14  is staked through one of two apertures  80 , depending on the desired amount of window opening, and is compressed, using a suitable tool or machine, until bottom portion  81  of rivet  14  is larger then diameter of aperture  80 . This type of connection will allow for sash arm  11  to pivot during normal operation. Rivet  14  may be composed of any suitable material known in the art, but not limited to metal or metal alloys, ceramic, pvc. In the present embodiment brass was the preferred material for the construction of rivet  14 . In addition, sash arm  11  is pivotally connected, to an intermediate location, to one end of support arm  22  by another suitable rivet  16 , connected by the same technique as rivet  14 . Sash arm  11  may be any suitable shape known in the art, but not limited to a square, rectangle, etc. In the present embodiment sash arm  11  is of generally rectangular shape with generally rounded inner and outer ends,  17  and  18  respectively, as seen in  FIG. 1 . Outer end  18  may be crimped so as to form half of an octagon, as seen in  FIG. 1 . Sash arm  11  has top and bottom surfaces,  19  and  20  respectively, along with a generally circumferential side wall  21 . Top surface  19  of sash arm  11  may taper downward near inner end  17  of sash arm  11 , or it may be even with the plane of top surface  19 . Sash arm  11  may have a dimple  21 , or protrusion, on bottom surface  20 . Dimple  21  may be of any suitable shape known in the art, but not limited to circle, square, rectangle, etc. In the present embodiment dimple  21  was generally cylindrical in shape. In normal operation dimple  21  will contact circumferential sidewall  25 , thus preventing sash arm  11  from pivoting passed a certain point, predetermined at manufacturing. Generally, dimple  21  can be positioned on sash arm  11  so as to allow sash arm  11  to pivot from 0° to 90°. 
         [0021]    Support arm  22  may be of generally the same shape as sash arm  11 , as seen in  FIG. 1 . Support arm  22  has top and bottom surfaces,  23  and  24  respectively, along with a generally circumferential sidewall  25 . Generally, support arm  15  is shorter in length then sash arm  11 . Support arm  22  may have rounded inner and outer ends,  26  and  27  respectively. In addition, support arm  15  may have an aperture located near outer end  27 , so as to allow for a pivotal connection between support arm  22  and sash arm  11 , as mentioned above. Furthermore, near inner end  26  there may be a bored cavity  28  to house post  90  and screw  29 ; bored cavity  28  may be of any general shape known in the art, but not limited to a circle, square, rectangle, etc. In the present embodiment the preferred shape was that of screw  29 , i.e. screw like, as seen in  FIGS. 1 and 2 . Bored cavity  28  has sidewalls  30  and  31 , along with front and rear walls  32  and  33  respectively. Support arm  22  may have a slit  34  adjacent to bored cavity  28 . Slit  34  may be used if additional leverage is needed to detach retaining clip  35  from adjustment mechanism  29 . Slit  34  may be of any suitable shape known in the art, but not limited to circular, oval, or rectangular. In the resent embodiment a generally circular shaped slit was the preferred shape. It must be pointed out that both sash arm  11  and support arm  22  may be constructed of any suitable material known in the art but not limited to metal or metal alloy, wood, polyvinyl chloride (pvc), etc. In the present embodiment the preferred material was metal. 
         [0022]    Retaining clip  35  may be constructed of any suitable material known in the art but not limited to metal or metal alloy, wood, polyvinyl chloride (pvc), etc. In the present embodiment the preferred material was a resilient type of metal, so as to allow for engaging support post  90 . Retaining clip  35  is slidably interconnected with support arm  22 . Retaining clip  35  has roughly “C” shaped edges  36  that hold retaining clip  35  to support arm  22  while allowing retaining clip  35  to traverse along support arm  22  when retaining clip  35  is disengaged from support post  90 . In addition, retaining clip  35  has a pair of flexible opposed arms,  38  and  39  that, when pressed against support post  90 , engage groove  92 , by means of a friction or pressed fit. 
         [0023]    Track  70  may be constructed of any suitable material known in the art, but not limited to metal or metal alloy, ceramic, polyvinyl chloride (pvc), etc. In the present embodiment the preferred material for the construction of track  70  was metal. Track  70  may be composed of a generally horizontal elongated track portion  71 , having a plurality of longitudinally spaced apertures  72  therein, through which project fasteners for mounting horizontal track portion  71  to window opening, any suitable type of fastener known in the art but not limited to a screw, nail, tack may be used. In the present embodiment the preferred fastener was wood screws. Horizontal track portion  71  may be generally rectangular in shape, as in the present embodiment, but any suitable shape known in the art may be used. In addition horizontal portion  71  has top and bottom surfaces,  76  and  77  respectively. In one embodiment track  70  also may have a vertical portion  73 , which may be perpendicular to horizontal elongated track portion  71 , so as to form a right angle with horizontal track portion  71 . Vertical portion  73  may have an arcuate lip  74  which may be integrally formed therewith and may traverse longitudinally from one end of track  70  to a point located passed the mid-portion of track  70 . Arcuate lip  74  acts as a guide for shoe block  13 , and thus allows shoe block  13  to slide across horizontal portion  71  in a uniform fashion, and retain shoe block  13  thereto. 
         [0024]    In yet another embodiment horizontal track  70  may not have a vertical portion, but rather horizontal track portion  71 , may have a rib located on top surface  76  of horizontal track portion  71 , and a parallel groove on the base of shoe block  13 . In that embodiment shoe block  13  would traverse along the rib of horizontal surface  76 . 
         [0025]    Shoe block  13  may be of any suitable shape known in the art but not limited to a square, rectangle, and triangle. In the present embodiment the preferred shape for shoe block  13  was a generally rectangular shape with rounded outside corners  78 . In addition, shoe block  13  may be constructed from any suitable material known in the art but not limited to metal or metal alloy, plastic, glass filled nylon or any equivalent. In the present embodiment the preferred material for construction of shoe block  13  was plastic. Shoe block  13  has a keeper arm  75  that traverses longitudinally across back edge  76  of shoe block  13 . Shoe block  13  may be constructed with a plurality of apertures. In the present embodiment shoe  13  has two circular apertures  80  located near outside corners  78 . As mentioned previously shoe block  13  is pivotally connected to sash arm  11  by of rivet  14 . Rivet  14  is staked through one of apertures  80 , depending on the desired amount of window opening, and is compressed, using a suitable tool or machine, until bottom portion  81  of rivet  14  is larger then diameter of aperture  80 . This type of connection will allow for sash arm  11  to pivot during normal operation. Shoe block  13  may be reinforced with additional material so as to add for added strength and longer use. In the present embodiment shoe block  13  has two pieces of reinforcing metal located inside of shoe block  13 , underneath apertures  80 . 
         [0026]    As mentioned previously support post  90  and threaded adjustment screw  29 , are located on top surface  76  of horizontal track portion  70 , fixed at a position that will allow for optimum performance of hinge. Support post  90  may be a generally cylindrically shaped rivet, but any suitable shape known in the art may be used. In one embodiment support post  90  may have a generally concave bored portion on outside surface. Support post  90  may be composed of any suitable material known in the art, but not limited to metal or metal alloys, ceramic, pvc, etc. In the present embodiment the preferred material for the construction of support post  90  was brass. Support post  90  may be connected to horizontal surface  70  in the same manner as rivet  14 . Support post  90  may have a circumferential groove  92  located on the outside top surface  91 , for engaging flexible arms  38  and  39 . In addition an aperture  93  may be located near the center of support post  90 , for receiving threaded adjustment screw  94 ; aperture  93  may be threaded, or smooth, depending on the screw type. Threaded screw  94  may be of any suitable shape type known in the art, in the present embodiment a threaded screw  94 , with crossed slots capable of accepting a Philips head screwdriver, was preferred. One could also have used a variety of other suitable types of screws known in the art, but not limited to a single slot type screw to accept a flat head screwdriver, or a hexagonal aperture to accept an Allen wrench, etc. Furthermore, one may use a knurled or square head style screw rather then a screw that requires a tool for rotation. With that embodiment, in normal operation, one could use the surface of ones finger to adjust the screw. Screw  94  of the present invention may be situated inside of bored cavity  28  so that the area of screw  94  that accepts the tool, or in the case of a knurled screw, the finger, is placed adjacent to front wall  32  of bored cavity  28 . 
         [0027]    The functionality of the hinge of the present invention is as follows. As mentioned above, sometimes casement windows will begin to sag, “sash sag”. This sag may occur before or after installation. Conversely, sash sag may occur after repeated use of the window  10 , i.e. opening and closing. In order to compensate for the sag the user will open window  10  so as to allow sash  12  to be fully extended outward. The user will then apply a force to retaining clip  35 , which will disengage retaining clip  35  from circumferential groove  92 . This will allow the user the capability of raising support arm  15  over adjustment mechanism  29 , and thus, allow access to adjustment mechanism  29 . Once the user has access to screw  94 , the user can easily turn screw  94  to compensate for the unwanted sash sag. After the adjustment has been made, the user will then return support arm  15  back over adjustment mechanism  29 , and press retaining clip  35  back around circumferential groove  92 . 
         [0028]    In the view above it will be seen that several objects of the invention are achieved and other advantageous results attained. 
         [0029]    As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense.