Abstract:
A protective additional glazing system, apparatus, and associated methods is disclosed for the protection of structural openings against impacts from projectiles from any cause, including nature or man. The system consists of a substantially rigid panel, substantially the same size as the visible glass being protected, that may be attached to the inside of the frame mounting the original glass via a standoff/anchor that is attached to the original frame via an adhesive means. Another embodiment consists of a substantially rigid panel cut slightly larger than the visible original glazing being protected, said panel being attached to the structural opening via a standoff/anchor/adhesive means. This invention provides security and protection in an effective and affordable manner.

Description:
FIELD OF THE INVENTION 
       [0001]    The glazing of windows and doors with clear rigid panels and the use of window films for safety and security are used in many different industries and has a very significant presence within the building industry and for some vehicles (busses for example). In nearly all of these instances they are framed in a manner similar to that typically found in common building practice. This is true even for ballistic protection, where the panel may be placed as double glazing in front of original glass, once again in typical and separate framing supports. 
       DESCRIPTION OF THE RELATED ART 
       [0002]    In an increasing violent society, businesses, educational institutions, and homes are subject to an increased number of threats against life, liberty and property. These threats can include ballistic threats, threats of explosive blasts, forced entry threats, and others. Businesses and homes in areas of high crime are increasingly forced to employ security measures to protect against these threats. These security measures can include the installation of glazing with increased strength. For example, bullet resistant glazing or glazing that can resist various impacts and attempts at intrusion are finding their way onto both residential and industrial buildings. Additionally, window films are marked with security claims that they protect against intrusion and projectiles from would-be perpetrators. 
         [0003]    Buildings in areas that are subject to natural disasters, such as hurricanes, tornadoes and other severe storms, require weatherproofing and additional protection from the elements. With climate change concerns, families, businesses, and governments seek effective yet low-cost means to protect structures and lives. 
         [0004]    Several products are available to protect inhabitants of buildings from intrusion by unwanted humans or wind-born debris: new windows/doors with stronger glass, additional panels with mechanical attachments, and window films. Unfortunately, each has many negative attributes, one being cost for those alternatives that are truly effective against intrusion. 
         [0005]    For example, conventional security improvement schemes require that the existing window and frame be removed and replaced with a new, stronger glazing and framing system. Because the old windows and frames need to be removed first before the new windows and frames can be installed, the costs of such jobs are greatly increased. Moreover, lead times to supply the frames and glazing and the area downtime, that is, the time required for workmen to come in, tear down the existing structure, and install the new structure, is also substantial. Furthermore, there is a risk of contamination to the work-area resulting from the demolition and reconstruction of the frame and surrounding building structure. This of course affects the occupants who need the building for their daily living or business needs. 
         [0006]    Another disadvantage of conventional schemes is that the noise, commotion and disruption inherent in tearing out the old frame and existing building materials, in addition to the significant down-time, precludes a discreet security enhancement. Because of the conspicuous nature of conventional schemes, they may unnecessarily cause fear in the workplace or unwittingly reveal to third parties the additional security measures. 
         [0007]    Conventional retrofit methods for increasing the security of a building are usually not aesthetically pleasing and leave unsightly anchoring, such as screws or other evidence of sizing the frame (e.g., cut marks, edges, and scratches). 
         [0008]    Once the typical new window glazing is in place, conventional frames do not allow for upgrades to glazing with a greater thickness. In order to upgrade with conventional frames, the entire frame must be removed and a suitable frame having dimensions to accommodate the glazing having a greater thickness must be installed. 
         [0009]    In many cases impact glass and window films are used to add security. However, with both of these solutions, under impact, the underlying glass is broken sufficiently to allow intruders to breech the protection, and the impact glass must be replaced adding cost, and disruption. The key to intrusion protection is keeping the intruder out for sufficient time to allow police to arrive. Window films and to a lesser degree impact glass cannot keep the intruder out. This is a key element that is not delivered by these methods. Given that the glass normally breaks with these methods, the entire glass and surrounding structure must be replaced. This a costly consequence of defeated glazing systems. More costly is that once the intruder is in, lives may be at stake. 
         [0010]    Another disadvantage is that conventional frames and methods to install them are costly, time-consuming with long lead times, and require two or more workers to aid in positioning the glass or glazing in the frames, and the normal operations of the building occupants is compromised especially if the weather or climate is inclement, requiring the addition of plastic sheeting etc., to protect the interior. 
         [0011]    Accordingly, there remains a need in the industry for an improved window and/or door protection system to fit the need that overcomes the advantages set forth previously. 
       SUMMARY OF THE INVENTION 
       [0012]    It is one object of the present invention to provide an improved system for supporting and holding a secondary security glazing panel without the need to remove or replace an existing glazing and existing frame. 
         [0013]    It is another object of the present invention to provide an improved and robust attachment system that adjusts to glazing of different thicknesses, lengths, and widths. It is another object of the present invention to provide an improved installation process that does not disturb the interior environment by retaining the original glazing such that the previous envelope is never disturbed or penetrated. 
         [0014]    It is another object of the present invention to provide a security solution that is virtually un-noticeable, aesthetically pleasing, and which does not use any screws requiring drilling into the existing framework which may compromise the warranty of the existing glazing. 
         [0015]    It is also an object of the present invention to provide an improved installation that is cost-effective and a method of installing that is suitable for one-person to handle that reduces the amount of time, cost, and effort involved in installation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1A  is a front elevation view of the invention covering a window frame. 
           [0017]      FIG. 1B  is a front elevation view showing how and where the panel is attached. 
           [0018]      FIG. 1C  is a top cross-sectional view highlighting two different standoff/anchor means. 
           [0019]      FIG. 2A  is a front elevation view of the invention covering a window on a door with minimal standoff distance supplied by the supporting frame. 
           [0020]      FIG. 2B  is a cross-sectional view from the side of the structure and invention in  2 A. 
           [0021]      FIG. 3A  is a front elevation view of a means to standoff and retain a panel with fluting that permits air to enter behind the panel. 
           [0022]      FIG. 3B  is a cross-sectional view of the panels and attachment system from  3 A. 
           [0023]      FIG. 3C  is a front elevation view of the placement of components from  3 A and  3 B. 
           [0024]      FIG. 4A  is a cross-sectional exploded view of a system in which a standoff distance may be increased beyond protective panel thickness. 
           [0025]      FIG. 4B  is a cross-sectional view of the system in  4 A. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0026]    Referring to the figures, exemplary embodiments of the invention will now be described. The exemplary embodiments are provided to illustrate aspects of the invention and should not be construed as limiting the scope of the invention. The exemplary embodiments are primarily described with reference to the figures. 
         [0027]    For purposes of this description the following definitions are being adopted. “Inside of Frame” means surface of the frame that is substantially perpendicular to both the protective panel and the glazing pane being protected. 
         [0028]      FIG. 1A  illustrates an elevation front view of a structure window frame  101  as might be found on typical store fronts, hospitals or schools, or commercial or residential buildings, in which the original glass is recessed within the frame  108  (not shown in  FIG. 1A ). The external perimeter of the face of panel  103  is bonded to standoff/anchor means  105  that is bonded to opening frame  101  using adhesive means  104 . By way of example, as a method of installation, (1) standoff/anchor means  105  may be bonded to the inside of the frame  101  (substantially perpendicular to panel and glass panes) via adhesive means  104  and (2) panel  103  is then mounted to standoff/anchor means  105  via adhesive means  104 . A sealant  102  may be applied at lines  102   a  for the purpose of preventing humidity, vermin, or other air-borne debris from entering behind the panel  103 . 
         [0029]    In some embodiments, panel  103  is typically shaped to the same dimensions of the visible underlying glazing being protected including, but not limited to, trapezoidal, circular, rectangular or oddly shaped openings. It may be clear or opaque, wood, metal, or plastic. In the preferred embodiment, a polycarbonate plastic may be used that permits light to pass yet is extremely strong against forces of nature or man. Panel  103  may be selected from, but is not limited to, Bayer Makrolon GP polycarbonate sheet material. Various other polycarbonate sheet materials may be used depending on the application, even up to ballistic grade. One potential panel material is Bayer Makrolon polycarbonate sheet, having a polished surface, is optically clear, can be UV stabilized, and is a transparent sheet product. It features outstanding impact strength, light weight, superior dimensional stability, high temperature resistance, and high clarity. Other polycarbonate sheet products can also be used offering a variety of physical properties useful for the intent of this invention. The thickness of the polycarbonate sheet products may range between 0.210″ and 0.500″. 
         [0030]    If the application is storm-related (e.g., for hurricane or typhoon), a triple wall, extremely light weight polycarbonate sheet may be used that could if wanted, permit air to enter the structure and is described in more detail below. 
         [0031]    Standoff/anchor means  105  may be selected from a range of materials including wood, metal, and plastic, however, in the preferred embodiment, aluminum may be chosen for its strength to weight ratio. The shape of standoff/anchor means  105  may take different forms. In two different preferred embodiments, right angle aluminum or box channel may be used as shown in  FIG. 1D . Standoff/anchor means  105  may have dimensions creating a standoff distance between the panel  103  and original glazing  108  of between 0.250″ to 1.500″. Standoff/anchor means  105  may have perpendicular cross-sectional dimensions (parallel to panel  103 ) of 0.500″ to 1.500″. 
         [0032]    Adhesive means  104  may be selected from a range of products. VHB tapes (“Very High Bond” tapes) may be optimal for multiple reasons including a) the bonding agent used strongly grips relevant metals, glass, and plastics and b) the foam between the bonding agent on each side serves as both a cushion and provides additional standoff distance that may protect the original window glass from impact. Lab-tested and proven under real conditions, VHB tape eliminates rivets, bolts, screws and welds, and the need to drill holes and to use screws, etc., that would mar the normally clean installation of the existing framework and likely void the window warranty. It forms strong bonds with polycarbonate, vinyl, plastics and both painted and unpainted metals. “VHB” is intended herein to be a generic term being sourceable from any manufacturer, e.g., 3M, Essentra, etc. 
         [0033]    In some embodiments, to prevent liquid, vermin, and other air-borne debris intrusion, a clear sealant  102  may be applied around panel  103  and opening frame  101 . This sealant should be compatible with the panel  103  and form a strong bond with it and all frame materials. It may be beneficial for the sealant to be able to expand and contract with the panels in heat, cold, direct sunlight, shade, etc. 
         [0034]    In most embodiments, edge banding  106  may be used to camouflage the view beneath. This camouflage feature is very important because it hides from view the standoff/anchor means  105  and the adhesive means  104 ; this feature helps good inhabitants not feel like they are incarcerated and fools crime perpetrators into not realizing the protection is in place making it more difficult to detect and overcome the system. Edge banding  106  may, for example, comprise a PVC tape with adhesive on one side; the other side may be color-matched to the frame for colors and textures including metallic views. Edge banding tape does not contribute to structural integrity. It is of particular importance for buildings that need to maintain their “curb appeal” (such as stores), and for educational institutions that desire a secure environment that does not appear to be fortress-like. The width of the edge banding  106  may be of a dimension to substantially hide the components beneath it. 
         [0035]    In other embodiments, a reinforcing mullion  107  may be added if the opening is of sufficient size that the panel  103  might deflect and impact the original glass. Such mullions are common in the industry, may be constructed from aluminium and other materials, and may be affixed to the original frame behind panel  103  via adhesive means or traditional hardware. Depending upon the size of the glazing being protected, a cushion made of spongy material may be located between the mullion and the original glazing to prevent or mitigate abrupt movement of the mullion into the glass. In an alternative embodiment, instead of a mullion, a cushion of variable height could be adhered to either the panel  103  or the original pane  108  in approximately the center of the panels to cushion any potential impact between the pane and the panel. 
         [0036]      FIG. 1B  illustrates a front-elevation exploded view. Original glazing  108  mounts in existing frame  101 . On each of the two outside faces of angle standoff/anchor means  105   a,  one or more strips of double-sided adhesive means  104   a  (perpendicular to panel  103 ) and  104   aa  (parallel to panel  103 ) is affixed. The outside face of standoff/anchor means  105  (perpendicular to panel  103 ) is affixed to the inside of frame  101  via adhesive means  104   a.  Standoff/anchors  105   abcd  are in place attached via adhesive means  104   abcd . Finally, panel  103  is attached to standoff/anchor means  105   abcd  via adhesive means  104   aabbccdd , etc. Edge-banding  106  beneficially camouflages anchor means beneath panel  103 . One may alternatively install adhesive means  104   aabbccdd  first on the perimeter of panel  103  and place the panel and adhesive means on  105   abcd.    
         [0037]      FIG. 1C  illustrates a top cross-sectional view of the various elements, including different means for maintaining stand-off distance via standoff/anchor  105   a &amp; b . Angle profile  105   a  and box channel profile  105   b  are shown and may be used. Panel  103  may be installed in frame  101  via the following: Angle  105   a  or box channel  105   b  is attached to the perpendicular wall of frame  101  via adhesive means  104   a  and  104   b  respectively; panel  103  is then bonded to standoff/anchor means  105   a  or  105   b  via adhesive means  104   aa  and  104   bb ; and edge-banding  106  may then properly cut and applied around the perimeter of panel  103  over any visible standoff/anchor means. Sealant  102  may be applied around the edges of panel  103  at or over its junction with panel  101  to add additional bonding between the frame and panel and to seal out weather and vermin. In this manner, original glazing  108  is protected. 
         [0038]    Important to the protection of the original glass pane  108  is the standoff distance  112  between original glass panel  108  and panel  103 . It is preferred that the deflected panel  103  not come in contact with original pane  108 . It is also preferred for sufficient bonding surface to be available on frame  101  for adhesive means  104  to adhere for maximum bonding strength. Standoff distance  112  is dependent on the size of the opening being protected with large panes requiring more standoff distance to absorb impacts before recoiling to the pre-impact conformation. In the preferred embodiment, 1 inch may be generally specified. 
         [0039]      FIG. 2A  illustrates an “on-frame” embodiment that may be bonded on the outside of any frame containing a glazing, e.g., a door containing a glazing or a window containing a glazing. This embodiment may be preferable for openings in which there is a minimal standoff distance (in this case a door), meaning the distance from the outside of glass pane  208  to the exterior of the door skin  201  is minimal such that there or would be insufficient stand-off distance to permit panel flexing that upon impact may contact and break glass pane  208  or insufficient perpendicular frame wall surface on which to bond a standoff/anchormeans. Adhesive/standoff means  211  may be applied to the perimeter of the inside face of panel  203 . This assembly is then bonded to the outer skin of the opening framing  201 . Panel  203  would be cut with final dimensions slightly larger than the original visible glazing  208  being protected with at least 0.750 inches being recommended. Once panel  203  is secured, sealant  202  may be added around the perimeter between panel  203  and framing  201  to add additional strength and to prevent moisture, gasses, and vermin from entering behind the panel. Edge banding  206  may be applied to camouflage the protective elements for reasons already explained. The previous discussion provides an example of how to assemble the components (and their order) and is not intended to limit the multiple paths that could be used to assemble the system. 
         [0040]    It is important to note that additional standoff via adhesive/standoff means  211  is achieved because different adhesive tapes have core/substrates that may come in varying depths, thus additional standoff can be achieved with thicker foam core/substrates. In an alternative embodiments, plastic, metal or wood strips of rectangular cross section can be added as a standoff with additional strips of double sided adhesive around the same perimeter. 
         [0041]      FIG. 2B  illustrates a cross-sectional side view of an opening which in this case is a door. Original glazing  208   b  set in frame  201   b  is being protected by the invention. 
         [0042]    Adhesive means  204   b  bonds the panel  203   b  to the door skin  201   b.  Edge banding  206   b  may be applied to hide components below it and may match the color of the opening. Sealant  202   b  may be applied around the polycarbonate sheet  203   b.    
         [0043]      FIGS. 3A &amp;B&amp;C illustrates another embodiment of the invention useful in hot and hurricane prone environments in which users wish to have impact protection and air ventilation prior to, during, and immediately after a storm. This embodiment may use a multiwall (ribbed) version panel  303  which is significantly lighter than solid polycarbonate or plywood paneling.  FIG. 3A  is a front view of the panel system while  FIG. 3B  is a side view of the panel material. The multi-wall ribs  303   r  in the panel allow air to pass through it. This feature of the multi-wall panels may be used in creating the standoff/anchor means  306  that is used to anchor the panel to the opening while permitting air to pass behind the panel. This air flow creates ventilation for the opening and structure. In this embodiment, the panel  303  is applied as an on-frame installation with a standoff/anchor means created by utilizing fluted panel material  306  cut into strips between 0.500 and 2.000 inches wide and affixed between the entire panel&#39;s internal perimeter and the face of the frame and/or wall of the building. As this embodiment is intended to be employed as a temporary device to protect against hurricane debris and winds in lower wind zones (one and two), interlocking removable tape systems like DualLock™ and/or Velcro® tape  305  attachment means may be used to allow removal and reapplication. 
         [0044]    For higher wind zones, another embodiment of the invention may use cargo type belts  314  as an additional anchoring means to affix panel  303  to the structure of the building. Strap brackets  313  in to which cargo type belts  314  thread, may be removable. In this embodiment, these plate metal brackets may have “keyhole” openings to allow easy installation and removal. Hurricane rated anchors with exposed heads may be used in the bracket slots, and bolted to the structure with approved hurricane anchors. The panel may be bonded to the building frame via attachment means  305  which may be “VHB snap back tape”. This Velcro type system uses “mushroom” shaped caps which interlock creating a secure form of attachment which is easily applied with pressure until a “snap” is heard, confirming that the panel is securely attached to the building. The panel can be applied and removed hundreds of times. One side of the two piece tape system may remain permanently on the building while its mate may be permanently attached to the panel. 
         [0045]      FIG. 3C  illustrates the method and placement of the various components to protect original pane  308   c.  Opening  301   c  may be thoroughly cleaned with various cleaning solvents where it will contact the adhesives. Standoff/anchor means  306   c  is prepared by cutting strips from panel  303   c  and matching the needed perimeter dimensions of  303   c  to exceed the original glazing&#39;s visual size by at least one-half in each relevant dimension. Adhesive means  318   c  are cut into strips and adhered to opposite sides of standoff/anchor  306   c  (front and back). Standoff/anchor  306   c  may then be mounted on opening frame  301   c  after which panel  301   c  may be adhered to the adhesive strip  318   c  facing it. 
         [0046]    Nothing in this description is intended to preclude the preparation of this system at a location away from the job site. For instance, with dimensions of a particular job, preparers may precut the panels and the standoffs. As the adhesive means may typically be double-sided with pull-away backings, preparers may affix one side of the adhesive to both sides of a standoff  306   c.  At the job site, the remaining backings would be removed enabling the proper placement of the components. For additional ventilation, two or more layers of the ribbed panel material may be built up via a bonding agent, thus increasing the standoff distance from the opening. If this system is intended to be temporary, 
         [0047]    The standoff  306   c  may be bonded to the frame via the “snap back” system described in  FIG. 3A  above. With this embodiment, a standoff separation from the glass  308   c  is accomplished in this manner, using both the depth of the opening&#39;s original frame  301  and the standoff created from panel material  306 . 
         [0048]      FIGS. 4A &amp;B illustrate another embodiment to protect original pane  408  that is set within an opening  401  that provides minimal standoff depth (from pane to outside skin, door skin  401   a  in this case). In this embodiment a Z bar channel  419  may be utilized. Panel  403  is pre-cut to the dimensions of the visible glazing to be protected plus at least three-fourths inches in each dimension. The adhesive means  404   b  may be double-sided and adhered in advance to external perimeter of panel  403  and/or the underside of standoff/anchor means  419  at underside of arm  419   a.  Adhesive means  404   a  (may be the same product as  404   b ) may be adhered in advance to standoff anchor means  419  at underside of arm  419   c.  The standoff distance may be increased depending upon the width of standoff/anchor  419  center arm  419   b : increasing this width would cause panel  403  to be further from original pane  408 . Methodically, panel  403  may first be adhered to standoff/anchors  419  at the underside of  419   a  around its entire perimeter. Next, the remaining backing on  404   a  may be removed and the assembly comprising standoff/anchor means  419  &amp; panel  403  would be adhered to door skin  401   a  after preparation of the adherence site on door skin  401   a.    
         [0049]      FIG. 4B  further illustrates in a cross-sectional view how this system increases the standoff distance  412  because panel  403  is held off of the door skin via standoff/anchor means  419  because of panel  403 &#39;s bonding at the underside of arm  419   a.  The standoff distance  412  is again determined by the length of middle iron  419   b.    
         [0050]      FIG. 4B  also illustrates an alternative embodiment to increase the strength of the system. Standoff/anchor means  424  may be placed around the inside perimeter of panel  403  and make contact with the door skin  401   a;  this may be comprised of one or more strips double-sided adhesive means that may have a thicker core  424   m  to achieve standoff distance OR it may be comprised of a sandwich of components having a strong, thick material (like wood, metal, or plastic) to increase standoff distance of any thickness  424   q  sandwiched between one or more double-sided adhesives  424   p  and/or  424   r  enabling the additional anchoring and standoff of panel  403 . As with the other embodiments, sealant  402  may be applied around the perimeter of the junction of arm  419   c  and skin  401   a  and at the junction of arm  419   a  and panel  403 . 
         [0051]    These last 2 embodiments may offer protection from storms using inexpensive, lightweight multiwall polycarbonate sheets in a removable (temporary) application. It is designed to replace plywood that is often used as an inexpensive (but ineffective) storm protection. Many of the qualities expressed above are retained in a non-permanent version that can be set up and removed many times as it is affixed to the building using VHB snap-back tapes. These tapes are composed of hundreds of mushroom caps that interlock to create a strong but removable attachment. 
         [0052]    It is worth noting that different types of adhesive means may be used. “Very High Bond” (VHB) tapes are permanent. If a snap lock type of VHB tape is used, the panel will be temporary and can be removed and reapplied several times, as would be relevant if the desired protection is wind-storm related. This feature may also allow the system to comply with the fire code for egress/ingress. The multi-wall polycarbonate panel is light emitting contrary to plywood room darkening properties. 
         [0053]    The use of decorative edge banding self-adhesive tapes on the outside edge of the panels to make the permanent installation seem almost invisible. 
         [0054]    In an alternative embodiment, a graffiti window film can be applied to protect panels from scratching and attempts to deface the panel, and to add another layer of UV protection.