Integrated power window operator

An assembly for opening and closing a window sash from and against a window frame including a motor mounted to a window sash and having an output drive shaft, an operator arm having one portion pivotally connected to the sash and a second portion operably connected to the frame, and a drive train operably connecting the motor drive shaft to the output arm for controlling pivotal movement thereof in relation to the sash. A clutch mechanism permits the operator arm to be selectively disconnected from the drive train to allow the sash to be manually opened. A housing, disposable in a cavity defined in a generally rectangular box shape on a sash side, encloses the motor, drive train, and clutch mechanism. The housing has finger-jointed ends which are adhesively bonded to matching finger-joints formed on opposite sides of the sash cavity.

BACKGROUND OF THE INVENTION 
1. Technical Field 
The present invention is directed toward pivoting windows, and more 
particularly toward a powered operator for a casement window sash. 
2. Background Art 
Motorized casement window operators have been implemented in the art for 
mechanically opening and closing a window sash relative to a window frame. 
For example, Vetter U.S. Pat. No. 4,497,135, Berner et al. U.S. Pat. No. 
4,945,678 (Reissue U.S. Pat. No. 34,287), Midas U.S. Pat. No. 5,313,737, 
and Vetter et al. U.S. Pat. No. 5,493,813 all specifically disclose 
various motorized casement window hinges. In addition, it has been known 
to connect motor drives to the drive shaft of conventional manual window 
operators to retrofit such operators for motorized operation. 
However, these prior art are often difficult to retrofit into existing 
construction without requiring that the window frame and/or surrounding 
wall be destroyed to fit components. In some installations (such as areas 
with old wallpaper), the destroyed wall/frame parts cannot be readily 
repaired to their original condition. 
Further, with those prior art structures which can be more readily retrofit 
in existing installations, the resulting operator is generally obtrusively 
large. This tends to detract from the beauty of the wood or vinyl wrapped 
window and/or intrudes into the desired visual opening through the window. 
Still further, with many prior art power window operators, there is an 
unacceptably high level of noise and high cost. Still further, 
retrofitting a power system to use the existing hardware results in very 
low operating speeds, since locating the retrofitted system at the optimum 
kinematic position is nearly impossible. Further, the prior art power 
window operators do not include the window itself in their design. This 
detracts from the window's aesthetic features, and makes it difficult to 
paint or stain the window, since the painter has to work around or cover 
up the implemented hardware for the power system. 
The present invention is directed toward overcoming one or more of the 
problems discussed above. 
SUMMARY OF THE INVENTION 
In one aspect of the present invention, an assembly is provided for opening 
and closing a window sash from and against a window frame. The assembly 
includes a motor mounted to a window sash and having an output drive 
shaft, an operator arm having one portion pivotally connected to the sash 
and a second portion operably connected to the frame, means for operably 
connecting the motor drive shaft to the operator arm for controlling 
pivotal movement thereof in relation to the sash, and means for 
selectively controlling the motor. 
In another aspect of the present invention, the assembly includes manually 
operable means for selectively releasing the operably connecting means to 
allow the sash to move independent of the motor drive shaft. 
In preferred forms of this aspect of the present invention, the operably 
connecting means includes a gear reducing train operably connected to the 
motor drive shaft, driving means operably connected to the gear reducing 
train, and means for operably connecting the driving means to the operator 
arm for controlling pivotal movement thereof in relation to the sash. 
In another preferred form of this aspect of the present invention, the 
assembly includes a housing disposable in a cavity defined in a generally 
rectangular box shape on a sash side, with the motor, the gear reducing 
train, the driving means, and the means for operably connecting the 
driving means to the operator arm being disposed in said housing. 
In another preferred form of this aspect of the present invention, an 
integral mounting structure is provided for mounting a window sash control 
system to a window sash. The structure includes a window sash on one side 
having a substantially rectangular box shape with a selected thickness, a 
generally box-shaped cavity defined in the one sash side with 
finger-joints on the sash at opposite ends of the cavity, the cavity 
having a depth substantially equal to the selected thickness of the one 
sash side, and a generally box-shaped housing having two end walls 
connected by two side walls with at least one closing wall connected to 
the end walls and the side walls, the walls defining an enclosure adapted 
to receive a window sash control system. The end walls have matching 
finger-joints which engage the finger-joints on the opposite ends of the 
sash cavity, and the side walls each have substantially planar outer 
surfaces, with the outer surfaces substantially conforming to the outer 
surfaces of the one sash side. 
In another preferred form of this aspect of the present invention, the 
housing walls are thermally non-conductive, and the housing finger-joints 
are adhesively bonded to the sash finger-joints. 
One object of the present invention is to provide a power window operator 
which does not interfere with or detract from the beauty of the window. 
Another object of the present invention is to provide a power window 
operator which will not intrude into the desired visual opening. 
Still another object of the present invention is to provide a power window 
operator which incorporates the window itself in its design. 
Yet another object of the present invention is to provide a power window 
operator with low noise levels and at a low cost. 
It is another object of the present invention to provide a power window 
operator having a high operating speed. 
It is still another object of the present invention to provide a power 
window operator which will not interfere with the maintenance of the 
window unit, such as painting, nor will it adversely affect the strength 
of the window unit over time. 
It is yet another object of the present invention to provide an housing 
structure for suitably mounting a window sash control system to a window 
sash. 
Still another object of the present invention is to provide a power window 
operator structure which may be easily retrofitted into existing 
construction.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring to FIG. 1, a power window operator generally indicated by 10 is 
mounted to a side of a window sash 12. The window sash 12 is, in a 
preferred embodiment, part of a casement window which is pivotally mounted 
to a window frame or jamb, shown generally in phantom at 14, by the power 
window operator 10 and a suitable casement hinge 16 secured to the 
opposite side of the jamb 14 and sash 12. 
It should be understood that though the description herein generally refers 
to casement windows, the present invention could also be used with a 
variety of different window types, including awning windows, french 
windows and skylights, as well as windows made of a variety of different 
materials, such as wood or vinyl wrap windows. 
Power window operator 10, which will hereafter be described, is only one 
example of a type of power window operator which would benefit from 
incorporating the present invention. Though the particular power operator 
structure such as disclosed herein may be advantageously used with the 
present invention, once a full understanding of the present invention is 
obtained, it should be recognized that still other operator configurations 
for moving the sash relative to the jamb could also be advantageously used 
with the present invention. 
Referring now to FIG. 2, the power window operator 10 is comprised of a 
motor 18, a gear reducing train shown generally at 20, a worm 22, a worm 
gear 24, and an operator arm 26. 
Power and control lines (not shown) are suitably connected to the motor 18. 
Preferably, such lines extend from the motor 18 to the jamb 14 in any 
suitable manner. For example, the lines can be secured along the operator 
arm 26. 
The gear reducing train 20 generally includes first through sixth gears 
27-32. Each of the first through sixth gears 27-32 has a large diameter 
portion and small diameter portion. The large diameter portion of each 
gear is generally indicated with the suffix "a", and the small diameter 
portion of each gear is generally indicated with the suffix "b". The motor 
18 drives a drive shaft 34, which has a drive shaft gear 36 operably 
secured to its end. 
The drive shaft gear 36 engages the large diameter portion 27a of first 
gear 27. The small diameter portion 27b of first gear 27 engages the large 
diameter portion 28a of second gear 28. The small diameter portion 28b of 
second gear 28 engages the large diameter portion 29a of third gear 29. 
The small diameter portion 29b of third gear 29 engages the large diameter 
portion 30a of fourth gear 30. The small diameter portion 30b of fourth 
gear 30 engages the large diameter portion 31a of fifth gear 31. The small 
diameter portion 31b of fifth gear 31 engages the large diameter portion 
32a of sixth gear 32. The small diameter portion 32b of sixth gear 32 is 
operably secured to worm 22. In the FIG. 2 embodiment, the first 27, 
second 29 and third 31 gears all rotate about a first axis 38, while the 
second 28, fourth 30 and sixth 32 gears, and the worm 22 all rotate about 
a second axis 40, which is spaced apart from and generally parallel to the 
first axis 38. 
It should thus be appreciated that the disclosed gear reduction structure 
is a preferred structure which will permit use of a small, low-power, 
inexpensive motor 18 despite the large loads which are often encountered 
during opening and closing of the window sash 12, whether to overcome wind 
loads (particularly on large window sashes) or to create a weather strip 
seal when closing against the jamb 14 or to break the seal when initially 
opening. 
The worm 22 engages the worm gear 24, rotating worm gear 24 about a 
generally vertical axis. A shaft 42 extends through the center of the worm 
gear 24 and is fixedly secured to one end of operator arm 26 so that the 
worm gear 24 and operator arm 26 pivot together. The other end of operator 
arm 26 is suitably secured to the jamb 14 to cooperate with the hinge 16 
at the top of the sash 12 so that the sash 12 will open and close relative 
to the jamb 14 in response to pivoting of the operator arm 26. 
For example, if a standard casement hinge typically has a sash arm secured 
along the sash 12, with one end pivotally secured to a shoe which is 
slidable along a track secured to the window jamb 14, and a support arm 
pivotally secured at one end to the jamb 14 and pivotally secured at the 
other end relative to the sash (typically pivotally connected directly to 
the sash arm). If the hinge 16 is such a standard casement hinge, the 
operator arm 26 would preferably be pivotally secured to the jamb 14 in a 
suitable manner, as by the pivot 44 and bracket 46 shown in FIG. 2. With 
such a configuration, a track 47 would preferably be secured to the jamb 
14 (similar to the track of the hinge 16) and support a sliding shoe 48 
thereon, with a sash arm 49 (shown broken away in FIG. 2) pivotally 
secured to the shoe 48 and suitably secured to the sash 12. 
Operation of the FIG. 2 embodiment is as follows. 
When the motor 18 is activated to open the window sash 12 from the jamb 14, 
the motor will cause drive shaft 34, and hence drive shaft gear 36 which 
is secured thereto, to rotate in a first direction. The gear reducing 
train 20 is responsive to the rotation of the drive shaft gear 36 and 
causes the worm 22 to rotate at a reduced rate with respect to drive shaft 
gear 36. Rotation of the worm 22 about the second axis 40 causes the worm 
gear 24 to rotate which in turn pivots the secured operator arm 26. Due to 
the geometry of the hinge 16 and the operator 10, pivoting of the operator 
arm 26 relative to the sash 12 will cause the sash 12 to move relative to 
the jamb 14, with the operator arm 26 pivoting relative to the jamb 14 
about pivot 44, and the sash arm 49 in turn pivoting about the shoe 48 
which slides along the track 47. 
In the embodiment shown in FIG. 2, when the motor 18 is rotated in the 
direction opposite the first direction, the driving force will pivot the 
worm gear 24 and operator arm 26 in the opposite direction toward closing 
the sash 12 against the jamb 14. 
It should be noted that the exact number and placement of gears 27-32 
comprising the gear reducing train 20 is not imperative to the power 
window operator 10 of the present invention. Various numbers of gears, 
gear sizes and gear configurations can be implemented in the gear reducing 
train 20 without departing from the spirit and scope of the present 
invention. These variations will obviously depend many factors, including 
the size and shape of the window to be operably opened and closed, as well 
as the motor operation and the desired speed of moving the sash 12. 
A second preferred embodiment of the present invention is shown in FIGS. 
3-5. For ease of reference, components similar to components previously 
described in the embodiment of FIGS. 1-2 are designated with similar 
reference numerals, though with a "prime" added. 
FIGS. 3-5 show an a different power window operator 10' embodying the 
present invention. The operator 10' is ideally suited for use with a 
standard casement hinge such as previously described, as the worm gear 24' 
may be centrally located relative to the thickness of the sash 12' as best 
shown in FIG. 5, and therefore the sash arm 49' (see FIG. 5) may be 
readily aligned with the pivotal connection of the operator arm 26' to the 
sash 12', as is standard with casement hinges. As such, the operator 10' 
may be readily used in combination with a standard hinge on the top of the 
sash 12'. 
As with the FIGS. 1-2 embodiment, power and control lines (not shown) are 
suitably connected to the motor 18. Preferably, such lines extend from the 
motor 18 to the jamb 14 in any suitable manner. For example, the lines can 
be secured along the operator arm 26'. 
Referring to FIG. 3, the internal components of the window operator 10' are 
mounted inside a housing 52. Housing 52 includes sidewalls 56, 57, end 
walls 58, 59, and a closure wall 55 connecting the end walls 58, 59 and 
the sidewalls 56, 57. Housing 52 further includes a second closure wall 53 
generally conforming to the shape of the bottom surface of the sash 12'. 
Second closure wall 53 connects the end walls 58,59 and the sidewalls 
56,57 opposite closure wall 55. The housing 52 is disposable in a 
generally box-shaped cavity defined in one side of the sash 12'. 
In a preferred embodiment, the housing 52 has finger-joints 54 (best seen 
in FIG. 4) on end walls 58, 59 which engage matching finger-joints on 
opposite sides of the sash cavity, and may be suitably secured to the sash 
cavity by, for example, an appropriate glue or adhesive (depending on the 
materials of the sash 12' and the housing 52). 
It should be understood that though the above described housing is a 
preferred embodiment, in some installations the sash 12' may be big 
enough, or the below described components of the operator 10' small 
enough, so that the housing may be enclosed in a cavity with some of the 
walls being defined by parts of the sash 12'. Any such structure would be 
suitable so long as, in the preferred form, the outer surface would 
integrally conform with the basic outer surface of the sash surrounding 
the cavity. 
In a preferred embodiment, the housing 52 is made of a thermally 
non-conductive material. Further, while the housing 52 herein is generally 
described for use with a power window operator 10', it should be 
recognized that the housing 52 could be implemented as an integral 
mounting structure for mounting any of a variety of window operating 
systems, including but not limited to, a power window lock. 
The housing 52 is partially removed in FIG. 4 to show the internal 
components of the power window operator 10'. The power window operator 10' 
generally includes a motor 18 having a drive shaft 34 attached to a drive 
shaft gear 36', a gear reducing train shown generally at 20', a worm 22', 
a worm gear 24', and an operator arm 26' (shown in FIGS. 3 and 5). The 
gear reducing train 20' generally includes first through third gears 
27'-29'. As best shown in FIG. 5, each of the first through third gears 
27'-29' has a large diameter portion and a small diameter portion. The 
large diameter portion of each gear is generally indicated with the suffix 
"a", and the small diameter portion of each gear is generally indicated 
with the suffix "b". 
The drive shaft gear 36' engages the large diameter portion 27a' of first 
gear 27'. The small diameter portion 27b' of first gear 27' engages the 
large diameter portion 28a' of second gear 28'. The small diameter portion 
28b' of second gear 28' engages the large diameter portion 29a' of third 
gear 29'. The small diameter portion 29b' of third gear 29' is operably 
connected to worm 22' through a gear 66 having a diameter generally larger 
than the diameter of the worm 22' and located at a distal end of worm 22'. 
Gear 66 may be formed integral with worm 22' or fixedly secured to the 
distal end thereof. Gear 66 engages the small diameter portion 29b' of 
third gear 29' and rotates the worm 22' at the same rotational speed as 
gear 66. The worm 22' engages worm gear 24', rotating worm gear 24' about 
an axis generally perpendicular to the axis of the motor 18. 
Again, the exact number and placement of gears 27'-29' comprising the gear 
reducing train 20' is not imperative to the power window operator 10' of 
the present invention. Various numbers of gears, gear sizes and 
configurations can be implemented in the gear reducing train 20' without 
departing from the spirit and scope of the present invention. 
A cylindrical collar 68 extends through the center of worm gear 24'. The 
cylindrical collar 68 includes a bottom portion having outwardly 
projecting clutch teeth 70 which engage a cooperating set of inwardly 
projecting teeth 72 in a central opening in the worm gear 24' when the 
collar 68 and worm gear 24' are axially aligned. 
The collar 68 also has an upper portion 88 having a set of axially spaced 
teeth 80 basically forming a rack. Although it will become apparent 
hereafter that the teeth 80 actually need to be on only one side of the 
collar 68, in the preferred embodiment the teeth 80 extend around the 
collar upper portion 88 to ease in assembly (as this allows the collar 68 
to be assembled in any angular position). 
A spline shaft 74 extends through both the cylindrical collar 68 and the 
worm gear 24' and is suitably mounted to the housing 52 and/or sash 12' 
for pivoting about the same vertical axis as the worm gear 24'. The spline 
shaft 74 is also suitable fixed to a distal end of the operator arm 26' so 
that the shaft 74 and arm 26' pivot together. The spline shaft 74 includes 
outwardly extending clutch teeth 76 extending along its length, which 
teeth 76 engage a mating set of inwardly extending teeth 78 on an inner 
surface of cylindrical collar 68 to secure the collar 68 and shaft 74 for 
pivoting together. 
Operation of the embodiment shown in FIGS. 3-5 is similar to the operation 
of the embodiment in FIGS. 1-2. 
Specifically, when the motor 18 is activated to open the sash 12' from the 
jamb 14, the motor 18 turns the drive shaft 34 and drive shaft gear 36' in 
a first direction. The gear reducing train 20' is responsive to the 
rotation of the drive shaft gear 36' and causes the worm 22' to rotate at 
a reduced gear ratio with respect to the drive shaft gear 36'. In one 
preferred embodiment, for example, the gear reducing train 20' achieves a 
reduction ratio of approximately 750:1 (with such a reduction rate 
permitting use of a small, low-power, inexpensive motor 18 despite the 
large loads which are often encountered during opening and closing of the 
window sash 12' as previously described). 
Rotation of the worm 22' causes the worm gear 24' to pivot, which in turn 
pivots the cylindrical collar 68, which in turn pivots the spline shaft 
74, which in turn pivots the operator arm 26' to open or close the sash 
12' from or against the jamb 14 depending on the direction of pivoting of 
the spline shaft 74. That is, when the worm gear 24' pivots in a clockwise 
direction as viewed in FIG. 5, the sash 12' is closed toward the jamb 14, 
while counter-clockwise pivoting of the worm gear 24' opens the sash 12' 
away from the jamb 14. 
FIG. 4 also shows a clutch mechanism indicated generally at 90 which 
cooperates with the previously described cylindrical collar 68 to permit 
the operator arm 26' to be disengaged from the gear reducing train 20' to 
free the sash 12' for manual opening and/or closing such as might be 
desirable, for example, in the event of a power outage. That is, since the 
worm 22' effectively prevents backdrive to prevent the sash 12' from being 
moved except through pivoting of the drive train and worm 22', the clutch 
mechanism 90 disengages the operator 10' from the worm 22' to permit 
movement of the sash 12' even though the worm 22' is not rotated 
The clutch mechanism 90 includes a control gear 82 rotatably mounted in the 
housing 52 and engaging the axially spaced teeth 80 of the cylindrical 
collar 68 An actuator gear 84 is also mounted in the housing so as to 
engage the control gear 82, with a handle 86 operably secured to the 
actuator gear 84 and projecting from the housing 52 (see FIG. 3) to permit 
manual pivoting of the handle 86. 
As generally viewed in FIG. 4, clockwise pivoting of the handle 86 causes 
the actuator gear 84 to also rotate in a clockwise direction. This causes 
the control gear 82 to rotate in a counter-clockwise direction and, though 
its engagement with the collar axially spaced teeth 80, slides the 
cylindrical collar 68 upwardly on the spline shaft 74 sufficiently to 
disengage the clutch teeth 70 on the bottom portion of cylindrical collar 
68 from the clutch teeth 72 on the inner surface of worm gear 24'. 
Accordingly, the spline shaft 74 and connected operator arm 26' may pivot 
independently of the worm gear 24' to permit manual moving of the sash 
independent of the motor 18, drive train, worm 22' and worm gear 24'. 
It should thus be apparent that operators made according to the present 
invention may be readily integrated into the design of the window without 
detracting from the beauty of the window, and may be used even in retrofit 
installations without intruding into the desired visual opening of the 
window. Retrofitting, in fact, may be easily accomplished by simply adding 
a new sash incorporating the invention of the present invention, with only 
minimal modifications required of the existing construction to accommodate 
power and control cables. In this regard, the integrated design of the 
operator also will not interfere with the maintenance of the window unit, 
such as painting, nor will it adversely affect the strength of the window 
unit over time. 
It should also be apparent that operators made according to the present 
invention may be made at relatively low cost despite the small space 
within which the drive components must be fit, since the operator allow 
for the use of low-power and therefore inexpensive motors while still 
maintaining the desired driving power and speed. 
It should further be apparent that operators made according to the present 
invention will operate at low noise levels within the building. Not only 
is the motor completely enclosed in a housing to deaden sounds, but the 
motor is also located in the sash at a point which maximally spaced from 
the building interior. Moreover, through most of the sash's range of 
motion, the motor is actually disposed outside the building so that much 
of whatever noise does escape the housing will disperse outside the 
building. 
Still other aspects, objects and advantages of the present invention can be 
obtained from a study of the specification, the drawings and the appended 
claims.