WEATHERSTRIP CARRIER THAT REMOVABLY ATTACHES TO FENESTRATION UNIT

A weatherstrip carrier of a replaceable weatherstrip system for a fenestration unit includes a weatherstrip support configured to hold a weatherstrip. The weatherstrip carrier also includes a coupling member that is attached to the weatherstrip support. The coupling member is configured to removably attach to the fenestration unit. The coupling member includes a spine, a first projection, and a second projection. The first and second projections project from the spine in a common direction. The coupling member is resiliently flexible for movement between a neutral position and a flexed position. The first and second projections are biased toward each other when the weatherstrip carrier is in the flexed position. The second projection is configured to be removably received within the fenestration unit, with the weatherstrip carrier in the flexed position, and with the first and second projections cooperatively compressing against the fenestration unit to retain the weatherstrip carrier thereon.

TECHNICAL FIELD

The present disclosure generally relates to a fenestration unit and, more particularly, relates to a weatherstrip carrier that removably attaches to a fenestration unit.

BACKGROUND

Fenestration units, such as sliding doors and windows, may include features for managing rainwater, snow runoff, sleet, water from nearby sprinkler systems, and/or other water. These features may help divert water and/or channel water away from the interior of the structure.

However, several challenges remain in this regard. For example, some of these features may fail when subjected to extreme conditions and allow for undesirable water intrusion. Also, for fenestration units with an active or movable panel (e.g., a sliding door or window), these water diversion features may disadvantageously increase the operating force that is necessary for moving the panel. Furthermore, these features may present manufacturing difficulties, for example, by increasing part count, by increasing assembly time, by decreasing manufacturability, etc.

Thus, it is desirable to provide improved water management features for a fenestration unit, including features that provide more robust water diversion and other weather resistance. It is also desirable to incorporate such features without significantly increasing necessary operating forces for moving panels of the fenestration unit. Furthermore, it is desirable to provide weather management features that provide increased manufacturing efficiencies. Other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background discussion.

BRIEF SUMMARY

In one embodiment, a weatherstrip carrier for a fenestration unit is disclosed. The weatherstrip carrier includes a weatherstrip support configured to hold a weatherstrip. The weatherstrip carrier also includes a coupling member that is attached to the weatherstrip support. The coupling member is configured to removably attach to the fenestration unit. The coupling member includes a spine, a first projection, and a second projection. The first and second projections project from the spine in a common direction. The coupling member is resiliently flexible for movement between a neutral position and a flexed position. The first and second projections are biased toward each other when the weatherstrip carrier is in the flexed position. The second projection is configured to be removably received within the fenestration unit, with the weatherstrip carrier in the flexed position, and with the first and second projections cooperatively compressing against the fenestration unit to retain the weatherstrip carrier thereon.

In another embodiment, a method of manufacturing a weatherstrip carrier for a fenestration unit is disclosed. The method includes forming a weatherstrip support of the weatherstrip carrier. The weatherstrip support is configured to hold a weatherstrip. Moreover, the method includes forming a coupling member that is attached to the weatherstrip support. The coupling member is configured to removably attach to the fenestration unit. Forming the coupling member includes forming the coupling member to include a spine, a first projection, and a second projection. The first and second projections project from the spine in a common direction. The coupling member is resiliently flexible for movement between a neutral position and a flexed position. The first and second projections are biased toward each other when the weatherstrip carrier is in the flexed position. The second projection is configured to be removably received within the fenestration unit, with the weatherstrip carrier in the flexed position, and with the first and second projections cooperatively compressing against the fenestration unit to retain the weatherstrip carrier thereon.

In an additional embodiment, a fenestration unit is disclosed. The fenestration unit includes a frame and a panel that is supported by the frame. The fenestration unit also includes a weatherstrip system that is removably attached to the frame. The weatherstrip system includes a weatherstrip carrier and a weatherstrip. The weatherstrip carrier is configured to retain the weatherstrip against the panel. The weatherstrip carrier includes a spine, a first projection, and a second projection. The first and second projections project from the spine in a common direction. The weatherstrip carrier is resiliently flexible for movement between a neutral position and a flexed position. The first and second projections are biased toward each other when the weatherstrip carrier is in the flexed position. Also, the second projection is removably received within the frame, with the weatherstrip carrier in the flexed position, and with the first and second projections cooperatively compressing against the frame to retain the weatherstrip carrier thereon.

DETAILED DESCRIPTION

Broadly, example embodiments disclosed herein include a weatherstrip carrier of a weatherstrip system for a fenestration unit, such as a window, door, sliding door, etc. The weatherstrip carrier may support, hold, and retain a weatherstrip against a passive or active panel of a sliding door or horizontally-sliding window in some embodiments. The weatherstrip carrier may also removably attach to the frame of the fenestration unit with an attached weatherstrip substantially sealed against the panel to thereby divert water away therefrom. The weatherstrip may be removably attached to the carrier in some embodiments so as to be replaceable. In some embodiments, the weatherstrip carrier may removably clip, clamp, or otherwise compress against a frame of the fenestration unit. The weatherstrip carrier may resiliently and elastically deform from a neutral position to a flexed position. First and second members of the weatherstrip carrier may be resiliently biased toward each other to cooperatively compress against the frame, thereby retaining the carrier on the frame with the weatherstrip substantially sealed against the panel of the fenestration unit.

Furthermore, the weatherstrip carrier may include a first compression member and a second compression member (i.e., a first jaw-like projection and a second jaw-like projection) that are attached by a spine of the weatherstrip carrier. The second compression member may be received in an aperture of the fenestration unit frame, the spine may overlap and cover an exterior surface of the frame, and the second compression member may cooperate with the first compression member to grip onto and clip to the frame. The weatherstrip carrier may be resiliently flexed when removably attached to the frame such that the compression members are biased together and such that the compression members cooperatively clip to the frame of the fenestration unit. In this position, the weatherstrip may be supported on and sealed against the panel of the fenestration unit and angled away therefrom to divert water.

The weatherstrip carrier may include these and/or other features that provide highly robust weather resistance. These features may be incorporated without significantly increasing necessary operating forces for moving the panels of the fenestration unit. Furthermore, one or more features of the present disclosure may provide manufacturing benefits, such as lower part count, increased manufacturing efficiency, and/or other advantages.

Referring initially toFIG.1, a weatherstrip carrier102of a fenestration unit104is illustrated according to example embodiments of the present disclosure. The weatherstrip carrier102may be removably attached to the fenestration unit104and may hold a weatherstrip106against the fenestration unit104as will be discussed in greater detail below.

In some embodiments, the fenestration unit104may be a sliding door, and the majority of the discussion will refer to the fenestration unit104as such as an example. However, it will be appreciated that the weatherstrip carrier102may be configured for a horizontally-sliding window, a swinging door or window, or another type of fenestration unit104without departing from the scope of the present disclosure.

As shown inFIG.1, the fenestration unit104may include a frame110that supports a panel112. The panel112may be a passive or active panel of a sliding door. Although the panel112is schematically illustrated, it will be appreciated that the panel112may include a number of components, such as a bottom rail that supports a glass or other glazing unit and/or other components. The frame110may include a sill114. The sill114may include a base116and an exterior upstand118that projects upward from the base116in a vertical direction (opposite the direction of gravity). The sill114may also include an interior upstand120that also projects from the base116in the upward, vertical direction. The interior upstand120may be spaced from the exterior upstand118in a lateral direction. As such, a gap122may be defined between the exterior upstand118and the interior upstand120, and the base116may substantially close off the bottom side of the gap122. The frame110may further include a rail124that projects upward vertically from the base116.

The sill114may be elongate and may extend in a longitudinal direction along a longitudinal axis126. The cross-sectional profile of the side114may remain substantially constant along the axis126. The rail124may support sliding movement of the panel112of the fenestration unit104. More specifically, in embodiments in which the panel112is an active panel of a sliding door fenestration unit104, the rail124may support sliding movement of the panel112along the axis126(e.g., using one or more roller elements, roller element bearings, etc.).

As shown inFIGS.1-3, the weatherstrip carrier102may be an elongate, rail-shaped member that extends substantially parallel to the longitudinal axis126. The weatherstrip carrier102may have a generally F-shaped cross section in some embodiments (FIGS.1and3). The weatherstrip carrier102may generally include a weatherstrip support127and a coupling member128. The weatherstrip support127and the coupling member128of the weatherstrip carrier102are shown in isolation inFIGS.2and3for clarity. As shown, the carrier102may be a monolithic, unitary part in which the coupling member128and the weatherstrip support127are integrally attached. For example, the carrier102may be formed via an extrusion process in some embodiments for efficient manufacture such that the carrier102is unitary and monolithic.

The weatherstrip carrier102may generally include a spine140as shown inFIGS.2and3. The spine140may be a flat, generally planar strip that is elongate and that extends along the axis126. The spine140may have a first edge144and a second edge146and a width dimension measured therebetween. The spine140may be arranged such that the first and second edges144,146are spaced apart in the vertical direction. The spine140may also have an inner surface148and an outer surface149with a thickness dimension measured therebetween. The width of the spine140may be significantly greater than the thickness of the spine140, and the longitudinal length of the spine140measured along the axis126may be significantly greater than both the width and thickness dimensions of the spine140.

The weatherstrip carrier102may further include a first projection141. The first projection141may be wedge-shaped in cross section (FIG.3) and may be elongate (FIG.2) so as to extend along the axis126. The first projection141may be fixedly attached to the spine140and may project laterally from the first edge144of the spine140. The first projection141may have a lower inner surface152(i.e., an underside surface). The lower inner surface152may be substantially flat and planar. The first projection141may additionally include an upper exterior surface150that faces generally upward and opposite the lower inner surface152. The upper exterior surface150may be relatively flat and may be sloped relative to the vertical direction so as to define the wedge-shape of the first projection141. The first projection141may additionally include a leading end154that is disposed on the projected end of the first projection141(on the lateral side opposite the spine140).

The leading end154may include an aperture, such as an elongate groove155, a depth-direction of the groove155being directed laterally into the first projection141. The groove155may receive the weatherstrip106in some embodiments, for example, for removably receiving the weatherstrip106. Accordingly, the leading end154of the first projection141and the groove155therein may define the weatherstrip support127of the weatherstrip carrier102.

The weatherstrip carrier102may additionally include a second projection142. The second projection142may be a barbed or finned strip that projects laterally from the spine140. The second projection142may project from the spine140from an area that is spaced away from the second edge146of the spine140so as to define a flange180between the second edge146and the second projection142.

In some embodiments, the second projection142may include a base strip160that projects from the spine140laterally in the same direction as the first projection141. The base strip160may include an upper surface170that faces toward the lower inner surface152of the first projection141, and a lower surface172that faces in the opposite direction. The second projection142may also include a plurality (e.g., four) barbs162. The barbs162may be elongate and relatively flat, planar strips that project from the base strip160at an angle (e.g., at an approximately forty-five-degree (45°) angle) relative to the lateral direction. At least one of the barbs162may be angled away from the upper surface170and back toward the spine140, and at least one of the bars162may be angled away from the lower surface172and back toward the spine140. The barbs162may be resiliently flexible for flexure relative to the base strip160.

In some embodiments, the spine140, the first projection141, and the base strip160of the second projection142may be made of a first material, such as a first polymeric material, whereas the barbs162may be made of a second material, such as a second polymeric material. In some embodiments, the spine140, the first projection141, and the base strip160may be constructed from chlorinated polyvinyl chloride (CPVC) material, whereas the barbs162may me be constructed from a thermoplastic elastomer material of a higher flexibility. Thus, the material of the barbs162may have higher flexibility than the other portion of the carrier102. These different portions constructed from different materials may be integrally connected, for example, via a co-extrusion process such that the weatherstrip carrier102may be unitary and monolithic.

The carrier102may exhibit a degree of flexibility so as to move from a neutral position (shown inFIGS.2and3) to a flexed position represented inFIG.1. The carrier102may have enough resiliency to allow the first projection141and the second projection142to rotate and flex away from each other. In some embodiments, the vertical extension of the spine140may provide a type of living hinge for this resilient flexure. When flexed, the first and second projections141,142may be biased back toward each other (i.e., toward the neutral position). This biasing force may be utilized to attach the carrier102to the frame110as will be discussed.

As shown inFIG.3, the lower inner surface152and the upper surface170may be substantially planar and disposed at a non-zero angle153relative to each other when the carrier102is in the neutral position. The first and second projections141,142may be pivotally supported by the spine140. To flex the carrier102, the first projection141may resiliently deflect upward and rotate slightly away such that the angle153moves closer to zero (i.e., such that the surfaces152,170move toward a parallel arrangement. The carrier102may recover resiliently to restore the non-zero angle153.

Moreover, as shown inFIG.1, the weatherstrip carrier102may support a weatherstrip106. The weatherstrip106may include a flexible, elongate strip130of rubber or other polymeric material. The strip130may have a blade-shaped profile on one edge, and the opposite edge may be fixedly attached to a mounting member132of the weatherstrip106. The mounting member132may be a relatively stiff and rigid post or rail on which the strip130is fixed. In some embodiments, the mounting member132may be removably attached to the weatherstrip support127of the carrier102. For example, the mounting member132may be removably received within the groove155of the carrier102. Accordingly, the weatherstrip106may inserted, removed, and replaced manually for convenience. However, the strip130may be attached in other ways without departing from the scope of the present disclosure. For example the strip130may be attached and fixed in a more permanent manner (i.e., may be non-removable) in some embodiments of the present disclosure.

With the weatherstrip106attached to the carrier102, the coupling member128of the carrier102may be removably mounted on the frame110of the fenestration unit104. More specifically, the second projection142may be inserted and received within an aperture119of the upstand118of the frame110. The aperture119may be an elongate kerf that extends laterally into the upstand118and that extend longitudinally along the axis126. The second projection142may be inserted manually, the barbs162may resiliently bend during insertion, and the barbs162may thereafter bias against the internal surface of the aperture119to remain frictionally engaged to the frame110.

Furthermore, as the carrier102is advanced onto the frame110in the lateral direction, the surface152of the first projection141may slide over a horizontal upper lip surface131of the upstand118. This may resiliently deflect the carrier102and slightly pivot the first projection141away from the second projection142to change the angle153and seat the first projection141onto the upper lip surface131. The carrier102may continue to advance onto the frame110until the strip130abuts and resiliently flexes against the panel112. The strip130is shown in solid lines inFIG.1in an exemplary sealed position against the panel112. (A neutral, unflexed position of the strip130is shown in broken lines for comparison.) Furthermore, the carrier102may be advanced onto the frame102such that the spine140is layered over and covers part of an exterior-facing vertical surface133of the upstand118. The flange180of the spine140may abut against the frame110and may provide additional support for the carrier102as well.

When attached to the upstand118in the position shown inFIG.1, the carrier102may remain in its flexed position such that the first projection141is biased toward the second projection142. Accordingly, the first projection141and the second projection142may cooperatively compress against and grip the frame110to retain the carrier102thereon. Thus, the first projection141may be referred to as a first compression member or first jaw of the carrier102, and the second projection142may be referred to as a second compression member or second jaw of the carrier102. It will be appreciated that the clamping action of the carrier102and its resilient flexibility facilitates installation and removal of the carrier102. Furthermore, these features allow the carrier102to be manufactured efficiently (e.g., via an extrusion process).

The carrier102also retains the weatherstrip106for effectively diverting water runoff, etc. from the panel112and away from the gap122within the frame110. Also, the sloped upper exterior surface150may be sloped away from the panel112and sloped relative to the direction of gravity to further divert water runoff, etc. away from the panel112and the gap122within the frame110.

Referring now toFIG.4, additional embodiments of the carrier1102are illustrated. The carrier1102may be similar to the embodiments discussed above except as noted. Features that correspond to those ofFIGS.1-3are indicated with corresponding reference numbers increased by 1000.

The coupling member1128of the carrier1102may include the spine1140, the first projection1141, and the second projection1142. The coupling member1128may be configured to resiliently bias for compressing against a fenestration frame, similar to the embodiment ofFIG.1. However, the second projection1142may be shaped with a taper1143, and the second projection1142may project from the lower (second) edge of the spine1140. Furthermore, the weatherstrip1106may be fixedly and non-removably attached (e.g., molded) to the first projection1141.

Like the embodiments ofFIGS.1-3, the carrier1102and its weatherstrip1106may be conveniently and robustly attached to a fenestration frame for diverting water runoff, etc. away therefrom. Furthermore, the coupling member1128may provide the various manufacturing efficiencies discussed above.

Moreover, the weatherstrip systems ofFIGS.1-4may provide water diversion features without significantly increasing the operating forces necessary for opening the panel112of the fenestration unit. The weatherstrip106,1106may be biased toward the neutral position and may bias and move from the flexed position toward the neutral position, for example, when the panel112is part of a sliding door and the panel112moves along the axis126and out of abutting contact with the strip130. Furthermore, the panel112may move in the opposite direction and slide along the axis126, and the weatherstrip106,1106may resiliently flex from the neutral position to the flexed position to seal thereon.

In additional embodiments of the present disclosure, the second projection142,1142may vary from the illustrated embodiment. Instead of being integrally attached to the spine140,1140, the second projection142,1142may be removably attached to the spine140,1140. For example, the second projection142,1142may be a screw or other fastener that extends through the spine140,1140to fasten to the panel112. In addition, the first projection141,1141may flex resiliently to compress against the panel112, similar to the embodiments discussed above. Furthermore, it will be appreciated that the spine140,1140or other portions may be adhesively attached (e.g., via double-sided tape), or otherwise attached to the panel112without departing from the scope of the present disclosure.

Further, also the following examples are provided:

In an example, a weatherstrip carrier for a fenestration unit is provided that comprises a weatherstrip support configured to hold a weatherstrip and a coupling member that is attached to the weatherstrip support. The coupling member is configured to removably attach to the fenestration unit. The coupling member includes a spine, a first projection, and a second projection. The first and second projections are projecting from the spine in a common direction. The coupling member is resiliently flexible for movement between a neutral position and a flexed position. The first and second projections are biased toward each other when the weatherstrip carrier is in the flexed position. Further, the second projection is configured to be removably received within the fenestration unit, with the weatherstrip carrier in the flexed position, and with the first and second projections cooperatively compressing against the fenestration unit to retain the weatherstrip carrier thereon.

In an option, the first and second projections are pivotally supported for varying an angle defined therebetween as the coupling member resiliently flexes between the neutral position and the flexed position.

In an additional option, the first projection includes a substantially planar underside surface, and the second projection includes an opposing surface that opposes the underside surface. Further, the angle is defined between the underside surface and the opposing surface.

In an additional or alternative option, the first projection includes an exterior surface that is sloped. The exterior surface is also configured to be sloped relative to a direction of gravity when removably attached to the fenestration unit for weather runoff therefrom.

In a still further additional or alternative option, the second projection includes at least one barb that is resiliently flexible and that is configured to frictionally engage an interior surface of the fenestration unit.

In another additional or alternative option, the weatherstrip support is configured to removably attach to the weatherstrip.

As an option of the weatherstrip carrier, provided additionally or alternatively, the weatherstrip support includes an aperture that is configured to receive the weatherstrip.

As another additional or alternative option, the second projection includes a groove that is configured to removably receive the weatherstrip.

As a further additional or alternative option, the weatherstrip carrier is monolithic.

As another additional or alternative option, the weatherstrip carrier includes a first portion and a second portion that are integrally connected. The second portion is having a higher flexibility than the first portion, and the second portion is of a different material from the first portion.

As a further additional or alternative option, the spine includes a first edge and a second edge. The first projection extends from the first edge; the second projection is spaced from the second edge; and the spine includes a flange defined between the second projection and the second edge.

As an additional or alternative option, when the second projection is received in the fenestration unit, the spine is configured to at least partly cover an outward-facing surface of a frame of the fenestration unit, and the first projection is configured to at least partly cover a substantially horizontal lip surface of the frame with the weatherstrip substantially sealed against a panel of the fenestration unit.

As another option, provided in addition or as alternative, the first projection and the second projection are joined by a living hinge.

In another example, also a fenestration unit is provided that comprises a frame and a panel that is supported by the frame. Further, a weatherstrip system is provided that is removably attached to the frame. The weather strip system includes a weatherstrip carrier according to one of the preceding examples and a weatherstrip. The weatherstrip carrier is configured to retain the weatherstrip against the panel. The second projection removably received within the frame, with the weatherstrip carrier in the flexed position, and with the first and second projections cooperatively compressing against the frame to retain the weatherstrip carrier thereon.

In an example, also a method of manufacturing a weatherstrip carrier for a fenestration unit is provided that comprises the following steps: In one step, forming a weatherstrip support of the weatherstrip carrier is provided, the weatherstrip support being configured to hold a weatherstrip. In a further step, forming a coupling member that is attached to the weatherstrip support is provided. The coupling member is configured to removably attach to the fenestration unit, including forming the coupling member to include a spine, a first projection, and a second projection. The first and second projections are projecting from the spine in a common direction, and the coupling member is resiliently flexible for movement between a neutral position and a flexed position. The first and second projections are biased toward each other when the weatherstrip carrier is in the flexed position. The second projection is configured to be removably received within the fenestration unit, with the weatherstrip carrier in the flexed position, and with the first and second projections cooperatively compressing against the fenestration unit to retain the weatherstrip carrier thereon.

In an option of the method, forming the weatherstrip support and forming the coupling member includes integrally attaching the weatherstrip support and the coupling member.

In an additional or alternative option of the method, forming the weatherstrip support and forming the coupling member includes extruding the weatherstrip support and the coupling member in a single extrusion.

In another additional or alternative option, the method further comprises co-extruding the coupling member to include a first extruded portion and a second extruded portion of the coupling member. The first extruded portion has a higher flexibility than the second extruded portion.

In a further example, also a fenestration unit is provided that comprises a frame, a panel that is supported by the frame, and a weatherstrip system that is removably attached to the frame. The weather strip system includes a weatherstrip carrier and a weatherstrip. The weatherstrip carrier is configured to retain the weatherstrip against the panel. The weatherstrip carrier includes a spine, a first projection, and a second projection. The first and second projections are projecting from the spine in a common direction. Further, the weatherstrip carrier is resiliently flexible for movement between a neutral position and a flexed position, and the first and second projections are biased toward each other when the weatherstrip carrier is in the flexed position. Still further, the second projection is removably received within the frame, with the weatherstrip carrier in the flexed position, and with the first and second projections cooperatively compressing against the frame to retain the weatherstrip carrier thereon.

In an option, the panel is chosen from a group consisting of a sliding door active panel and a sliding door passive panel.

In an additional or alternative option of the method, the weatherstrip is removably attached to the weatherstrip carrier.