Window assembly and methods

A window assembly includes first, second, third, and fourth frame pieces connected together to form a rectangular frame. Each of the frame pieces has an inside face defining a glass-receiving groove and a muntin-engaging face orthogonal to the inside face and defining a muntin-receiving channel. A first muntin is oriented in the first frame piece muntin-receiving channel and the second frame piece muntin-receiving channel, and a second muntin is oriented in the third frame piece muntin-receiving channel and the fourth frame piece muntin-receiving channel. The first and second muntins cross over to engage at a first half lap joint. The frame pieces are connected to each other with rabbet joints. The window assembly can be part of a garage door arrangement. A method of making a window assembly includes connecting together the frame pieces with rabbet joints and orienting first and second muntins to engage at a lap joint. Methods of retrofitting existing windowless garage doors to include windows includes cutting a hole in the garage door and dropping a window assembly into the hole. The window assembly can then be removably secured to the garage door with fasteners.

TECHNICAL FIELD

This application relates to windows. In particular, this application relates to windows, methods of assembly, and mounting of windows, especially for garage doors.

BACKGROUND

Windows are used to provide exterior light into otherwise enclosed buildings. Windows are also used to enhance the attractiveness of enclosed buildings. They can also help to prevent criminal activity by allowing for the activities within an enclosed building to be visible from the exterior through the window.

Windows on garage doors are useful for all of these reasons. There is a need for an inexpensive, quick-assembled window that can be used in, for example, garage doors.

SUMMARY

A window assembly is provided including a plurality of frame pieces connected together to form a rectangular frame. The frame pieces are configured with appropriately provided grooves and channels to allow for a quickly-assembled window.

In one embodiment, the window assembly has first, second, third, and fourth frame pieces. Each of the frame pieces has first and second opposite ends, an inside face, and a muntin-engaging face. The inside face defines a glass-receiving groove therein. The muntin-engaging face is orthogonal to the inside face and defines a muntin-receiving channel. The frame pieces are connected together to form a rectangular frame. The frame pieces are connected together by rabbet joints, such that the glass-receiving groove of each frame piece is in communication with an adjacent glass-receiving groove. A first muntin is oriented in muntin-receiving channels of the frame pieces, and a second muntin is oriented in muntin-receiving channels of the frame pieces, such that the first and second muntins cross over to engage at a first half lap joint.

In another aspect, a garage door is provided. The garage door includes a door to selectively allow and prevent access to a garage interior. The door has at least one window assembly. The window assembly can be a type of window assembly as characterized above.

In another aspect, a method of making a window assembly is provided. The method includes providing first, second, third, and fourth frame pieces, each of the frame pieces having first and second opposite ends, an inside face, and a muntin-engaging face. The inside face defines a glass-receiving groove therein. The muntin-engaging face is orthogonal to the inside face and defines a muntin-receiving channel. The method includes connecting the first frame piece first end to the third frame piece first end with a rabbet joint. The first frame piece glass-receiving groove is arranged to be in communication with the third frame piece glass-receiving groove. The method includes connecting the first frame piece second end to the fourth frame piece first end with a rabbet joint, so that the first frame piece glass-receiving groove is in communication with the fourth frame piece glass-receiving groove. The method also includes orienting a first muntin in at least the first frame piece muntin-receiving channel. The method also includes orienting a second muntin in at least the third frame piece muntin-receiving channel to engage against the first muntin at a first half lap joint.

DETAILED DESCRIPTION

Reference is made toFIG. 1.FIG. 1illustrates a front elevational view of a garage10having a pair of garage doors12,14. Each garage door12,14can be mounted (e.g., rolling in tracks or the like) to selectively allow and prevent access to an interior in the garage10and is generally sized large enough to permit passage of a motor vehicle in and out of the garage10. As can be seen inFIG. 1, each door12,14has a plurality of window assemblies16. The window assemblies16allow for light transmittal into the garage interior, enhance the attractiveness of the garage10, and can prevent crime by allowing visibility into the garage interior from the outside.

FIG. 2illustrates one embodiment of window assembly16. The window assembly16illustrated inFIG. 2is shown in an exploded, perspective view and is one example only. The window assembly16shown inFIG. 2differs from the example window assemblies16shown inFIG. 1only in dimension and in the number of muntins. The principles explained regarding the window assembly16inFIG. 2can be applied to make windows of varying dimensions and number of muntins, as will be apparent to those skilled in the art.

In the embodiment ofFIG. 2, the window assembly16includes a first frame piece18. The first frame piece18is preferably a single-piece member or construction having a first end20and an opposite, second end22. The first frame piece18has an inside face24, an opposite outside face26, and a muntin-engaging face28extending between the inside face24and outside face26. As such, the muntin-engaging face28is generally orthogonal to the inside face24and to the outside face26. As can be seen inFIG. 2, the muntin-engaging face28defines at least one notch or muntin-receiving channel30. In the embodiment shown, the muntin-receiving channel30is centered between the first end20and second end22. In other embodiments, the muntin-receiving channel30can be off to one side or the other. Only a single muntin-receiving channel30is illustrated, and in other embodiments there can be multiple muntin-receiving channels30defined by the muntin-engaging face28. The muntin-receiving channel30is illustrated as having a generally rectangular cross-section, which matches the cross-section of muntins, described further below.

Still in reference toFIG. 2, the first frame piece18includes a first notch32at the first frame piece first end20. Similarly, there is a second notch34at the first frame piece second end22. The notches32,34cooperate with other frame pieces to form a rabbet joint, explained further below.

The inside face24of the first frame piece18defines a glass-receiving groove36therein. The glass-receiving groove36has a width and a depth sufficient to hold a typical pane of glass, such as a regular double strength glass or an insulated glass. Such a glass has a thickness of 0.5 inch or less. A pane of glass38can be seen in the exploded window assembly16.

Still in reference toFIG. 2, the window assembly16further includes a second frame piece42. In the preferred embodiment, the second frame piece42is constructed identically as the first frame piece18. As such, the second frame piece42includes a first end44, an opposite second end46, an inside face48, an outside face50, and a muntin-engaging face52. The muntin-engaging face52defines a muntin-receiving channel54arranged to be coaxial with the muntin-receiving channel30of the first frame piece18. The inside face48includes a glass-receiving groove, identical to the one shown at reference numeral36for the first frame piece18. The second frame piece42also includes a first notch56at the first end44, and a second notch58at the second end46.

The window assembly16further includes a third frame piece62. The third frame piece62has a first end64and an opposite second end66. The third frame piece62also has an outside face68and a muntin-engaging face70generally orthogonal to the outside face68. Orthogonal to the muntin-engaging face70and opposite of the outside face68is an inside face72. The inside face72has a glass-receiving groove identical to the groove shown at36for the first frame piece18. The muntin-engaging face70defines a muntin-receiving channel74therein. In the embodiment shown, the muntin-receiving channel74is centered between the first end64and the second end66. In the embodiment shown, the muntin-receiving channel74has a rectangular cross-section, generally matching a cross-section of muntins, described further below.

The first end64and second end66of the third frame piece62differs from the ends of the first frame piece18and second frame piece42. While the first and second frame pieces18,42have notches32,34,56,58, the third frame piece62has flat, flush ends64,66. These ends64,66cooperate with the ends of the first frame piece18and second frame piece42to form rabbet joints, as described further below.

The window assembly16further includes a fourth frame piece78. The fourth frame piece78is preferably identical to the third frame piece62. As such, the fourth frame piece78includes first and second flat, flush ends80,82, an inside face84, a muntin-engaging face86, and an outside face88. The inside face84defines a glass-receiving groove90extending between the first end80and the second end82. A muntin-engaging face86defines a muntin-receiving channel92, which in the embodiment shown, is centered between the first end80and second end82. In the embodiment shown, the muntin-receiving channel92is coaxial with the muntin-receiving channel74of the third frame piece62. The third frame piece62has a glass-receiving groove that is identical to the glass-receiving groove90. The first, second, third, and fourth frame pieces18,42,62,78cooperate to form a frame112. In the embodiment shown, the frame112is rectangular.

Also shown in the embodiment ofFIG. 2is a first muntin94and a second muntin96. Although only two muntins94,96are illustrated, it should be understood that more muntins or fewer or no muntins can be used in the window assembly16. The muntins94,96provide the appearance of dividing the glass pane38into smaller regions. In this embodiment, the first and second muntins94,96provide the appearance of four different sections of glass pane38. This can be seen inFIG. 1.

The first and second muntins94,96are preferably constructed identically to each other. The first muntin94has a first end98and an opposite second end100. Centered between the first end98and the second end100is a muntin-receiving channel102. Again, in other embodiments, the muntin-receiving channel102can be at a location other than centered between the first end98and the second end100.

The second muntin96has a first end104and an opposite second end106. In the embodiment shown, centered between the first end104and the second end106is a muntin-receiving channel108. After assembly, the muntin-receiving channel102of the first muntin94engages the muntin-receiving channel108of the second muntin96to engage at a first half lap joint110(FIG. 1). The half lap joint110is formed by an intersection or crossing over of the first muntin94and second muntin96such that there is a generally continuous, smooth intersection at the joint110.

As mentioned above, the first frame piece18, second frame piece42, third frame piece62, and fourth frame piece78are connected together to form a rectangular frame112(FIG. 1). The rectangular frame112can be a square, in some embodiments. The first frame piece first end20is connected to the third frame piece first end64by a rabbet joint. The rabbet joint is formed by the flush first end64engaging or being received by the first notch32, and the first frame piece glass-receiving groove36being in communication with the third frame piece glass-receiving groove (the one identical to the groove90). By the term “in communication”, it is meant that the groove is continuous such that the pane of glass38can be received within the groove without interruptions.

The first frame piece second end22is connected to the fourth frame piece first end80by a rabbet joint. Again, the flush first end80is received within the notch34of the first frame piece18. The glass-receiving groove36of the first frame piece18is in communication with the fourth frame piece glass receiving groove90.

The second frame piece first end44is connected to the third frame piece second end66by a rabbet joint114. The rabbet joint114is formed by the flush second end66being received by the first notch56in the second frame piece42. The glass-receiving groove of the second frame piece42is in communication with the glass-receiving groove of the third frame piece62.

The second frame piece second end46is connected to the fourth frame piece second end82by a rabbet joint116. In particular, the second end82is received by the second notch58of the second frame piece42. The glass-receiving groove90is in communication with the glass-receiving groove of the second frame piece42.

The window assembly16is formed so that the pane of glass38is received by and installed within the glass receiving groove of each of the frame pieces18,42,62,78. The first and second muntins94,96are placed over the glass38. In particular, the first muntin94is oriented in the first frame piece muntin-receiving channel30and the second frame piece muntin-receiving channel54. The second muntin96is oriented in the third frame piece muntin-receiving channel74and in the fourth frame piece muntin-receiving channel92.

The window assembly16is then complete and can be mounted in the garage door12,14. Typically, the garage door12,14has a hole cut into it, and the window assembly16is mounted in the hole and secured to the door12,14by, for example, screwing the frame pieces18,42,62,78to the door12,14with screws140(FIG. 4). The window assembly16is oriented on the garage door12,14such that the pane of glass38faces the exterior, while the first and second muntins94,96are oriented towards the interior of the garage10.FIG. 4illustrates the frame piece18secured to garage12,14with the screw140. Also illustrated inFIG. 4is trim or an overlay142mounted over the door12,14for decorative purposes. Although the frame piece18is the one illustrated, it should be understood that each of the frame pieces are mounted to the door12,14with, in the example shown, screw140. The use of screws140allows the window assembly16to be easily removable from the door12,14, in case glass38in the window assembly16needs replacement. The screws140allow for selective mounting and dismounting of the window assembly16into and out of the garage door12,14.

The window assembly16can be used to retrofit a pre-existing garage door that did not already have windows (a “windowless” garage door). To retrofit an existing garage door that does not have windows, holes are cut into the garage door sized to receive the desired shaped window assembly16. If desired, the garage door has an overlay mounted over the door for decorative purposes. The overlay can be boards, such as western red cedar boards that are nailed to the garage door. The overlay is mounted on the garage door such that it does not cover the exposed holes for receiving the window assembly16. After the holes are cut into the door, the window assembly16is dropped in so that it is received by the hole. If an overlay was provided, the window assembly16is dropped in or placed in the hole from the side without the overlay and pressed flush against the overlay. The window assembly16is then secured to the garage door using, for example, screws140to allow for selective removal of the assembly16in case, for example, the glass38breaks.

A second embodiment is shown inFIG. 3at16′. The window assembly16′ is identical to the window assembly16, except for the addition of third and fourth muntins120,122. The other structure is identical to the first embodiment, so the same reference numerals are used.

The third muntin120includes a first end124and an opposite second end126. Centered between the first and second ends124,126is a muntin-receiving channel128.

The fourth muntin122includes a first end130and a second end132. Centered between the first and second ends130,132is a muntin-receiving channel134.

The third muntin120is oriented in the first frame piece muntin-receiving channel30and the second frame piece muntin-receiving channel54. Preferably, the glass pane38is oriented such that it is between the third muntin120and the first muntin94.

The fourth muntin122is oriented in the third frame piece muntin-receiving channel74and in the fourth frame piece muntin-receiving channel92. The glass pane38is between the fourth muntin122and the muntin96. The third muntin120and the fourth muntin122cross over to engage at a second half lap joint136. In the particular, the muntin-receiving channel128engages the muntin-receiving channel134so that when the third and fourth muntins120,122are connected together in an overlapping fashion, the intersection is smooth and continuous. In preferred embodiments, the third muntin120is identical to the fourth muntin122.

A method of making a window assembly is provided. The method includes providing first, second, third, and fourth frame pieces, such as the frame pieces18,42,62, and78described above. The first frame piece first end20is connected to the third frame piece first end64with a rabbet joint. This is done such that the glass-receiving groove of each frame piece is in communication to be a continuous groove. The first frame piece second end22is connected to the fourth frame piece first end80with a rabbet joint. Again, the glass-receiving grooves are aligned to be in communication with each other and to be continuous. There is a step of orienting a first muntin94in at least the first frame piece muntin-receiving channel30and orienting a second muntin96in at least the third frame piece muntin-receiving channel74to engage against the first muntin94at the first half lap joint110.

The method further includes a step of inserting a pane of glass, such as glass38, into the glass-receiving grooves of the first frame piece18, third frame piece62, and fourth frame piece78.

The method also includes connecting the second frame piece second end46to the third frame piece second end66with a rabbet joint. Again, the glass-receiving grooves are aligned to be in communication with each other. Next, the second frame piece second end46is connected to the fourth frame piece second end82with a rabbet joint. The glass-receiving grooves are aligned to be in communication.

In one embodiment, after the steps of orienting first and second muntins94,96, there is the step of inserting a pane of glass38into the glass-receiving grooves of the first frame piece18, third frame piece62, and fourth frame piece78. After this step, a third muntin120is oriented in at least the first frame piece muntin-receiving channel30over the pane of glass38, and a fourth muntin122is oriented in at least the third frame piece muntin-receiving channel74to engage against the third muntin120at a second half lap joint. In this embodiment, there is further the step of connecting the second frame piece first end44to the third frame piece second end66with a rabbet joint, the glass-receiving grooves being in communication. Further, the second frame piece second end46is connected to the fourth frame piece second end82with a rabbet joint, and the glass-receiving grooves are in communication with each other.

The assembled windows16,16′ can then be mounted in the garage doors12,14. Of course, the window assemblies16,16′ can be used in structures other than garage doors.

The window assemblies16,16′ can be made from a variety of materials, and are preferably wood, in particular, cedar. In other embodiments, the windows16,16′ can be made from plastic or metallic pieces, or composites.

The window assemblies16,16′ can be built to custom size. Typical sizes include the frame pieces being made from pieces of wood two inches in width and one inch in thickness. The dimension of each window can typically be many different sizes, for example one foot by one foot, and larger.