Abstract:
A hinge for a hingedly movable sash in a window having a frame, including a track assembly having a track and a shoe engageable with the track and reciprocally movable along the track. The shoe presents a first rolling member at a first portion thereof and a bearing portion at a second portion. The shoe is shiftable between a window closed configuration in which the bearing portion contacts the track and transmits loads from the track to the sash arm and a window moving configuration in which the rolling member contacts the track and transmits loads from the track to the sash arm and rolls along the track as the shoe translates along the track.

Description:
CLAIM TO PRIORITY 
       [0001]    This application claims the benefit of U.S. Provisional Application 61/246,317 entitled “Concealed Casement Window Hinge With Roller and Integral Shipping Block” filed Sept. 28, 2009, the entire contents of which are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    With increasing demand for improved thermal performance of casement windows, and the desire for larger window openings, there is an increasing demand for casement window hardware that can handle increasingly larger and heavier window sashes. As sash size increases the load borne by casement window hardware increases dramatically. On prior art concealed casement hinges, the amount of friction between the sliding shoe and the track is one of the conditions that limit the maximum weight that a window hardware system can handle. As the window sash weight increases, the sliding friction in the hinge increases and greater loads are placed on the sash operator mechanism to overcome that friction. This can lead to premature failure of the operator mechanism. Increased sash weight also increases the amount of wear on the lower sliding hinge shoe. 
         [0003]    The potential for damage to the hinge during shipping and handling also increases as the sash weight is increased. Handling of window units during shipping is not always careful. When a heavy window unit is dropped, even from a small distance, high impact loads are transmitted though the hinges unless the sash is otherwise supported within the frame, such as by multiple shipping blocks wedged between the sash and frame. 
         [0004]    Shipping blocks fill the space between the frame and the sash and transmit loads encountered during shipping from the frame to the sash instead of to hinges or other hardware. Shipping blocks thereby prevent damage to the hardware. 
         [0005]    One prior attempt at a high-load capacity hinge included two rollers built into the shoe. A disadvantage of this hinge design, however, is that it requires additional shims, shipping blocks or other shipping preparations to prevent high impact loads incurred during shipping and handling from being transmitted directly onto the shoe rollers and axles. Otherwise, damage to the rollers and shoe can occur. This design also has two rollers to support the sash weight, adding to the complexity and increasing the part count of the hinge. 
         [0006]    Another problem encountered with prior hinges when used with the bending loads imposed by heavy sash components in the opening and closing process is that the sliding shoe may be broken or may become detached from the track due to breakage or deformation of the track. 
         [0007]    Accordingly, there is still a need in the industry for a high-load capacity casement window hinge that addresses the drawbacks of prior devices. 
       SUMMARY OF THE INVENTION 
       [0008]    Embodiments of the present invention address the need in the industry for a high-load capacity casement window hinge that overcomes the drawbacks of the prior art. A casement window hinge, according to embodiments of the invention, reduces the friction in the sliding shoe by using a single roller, and the shoe or a portion of the shoe also serves as a “built-in” shipping block when the window is closed. 
         [0009]    In one example embodiment, a single roller is incorporated into the sliding shoe to decrease the sliding friction between the sliding shoe and the track when the window is operated. A reduction of sliding friction in the hinge allows existing window operators to move larger and heavier sashes without exceeding the operator&#39;s strength and wear capabilities. The sliding shoe or a portion of the shoe also acts as a “shipping block” in the closed position. This feature allows impact loads perpendicular to the track to be transferred from the sash to the window frame without damaging the shoe roller. This feature also reduces the total number of shipping blocks that the window manufacturer needs to install by two. 
         [0010]    In embodiments of a hinge according to the invention, a portion of the underside surface of the shoe on an end opposite the roller has a slight upward angle. As the hinge is closed, a similarly angled offset surface or ramp on the sash arm contacts the top surface of the sliding shoe on the same end as the angled undersurface, urging the end of the shoe opposite of the roller downward until the angled surface confronts the hinge track. As this surface is pushed downward, the shoe pivots near the roller and lifts the roller off the track. This prevents damage to the roller during transit as the vertical forces are transmitted through the rigid shoe and not through the roller. 
         [0011]    In other embodiments of the invention, the shoe includes two segments, one which houses the roller and a second segment that acts as a shipping block or bearing portion. The two segments may include two separate pieces that interlock or the two segments can be molded as one component with a flexible member between the two segments. 
         [0012]    During operational movement of the hinge, the two shoe segments travel together in the channel of the track. The weight of the sash is carried by the segment of the shoe including the roller. When the hinge is closed, the sash arm travels on the top of the second segment. The second segment may be taller than the first segment and thus raises the sash arm slightly and transfers the weight of the sash from the roller segment to the second segment. The second segment thereby then acts as a shipping block when the window is closed. 
         [0013]    In another embodiment of the invention, a depressed surface or ramp on the sash arm pushes down on top of the second segment. This transfers the weight of the sash from the segment with the roller to the shipping block segment. This then causes the sash arm to rise slightly and transfers the load from the roller segment to the second segment, which then functions as a shipping block. 
         [0014]    In an embodiment in which the two segments are molded as two part of one component joined by flexible portion, the first segment houses a roller. The second segment is taller than the first segment and lifts the sash arm when it is in the closed position of the hinge. The lifting of the sash arm transfers the weight of the sash from the roller segment to the second segment thereby causing the second segment to act as a shipping block. 
         [0015]    In another embodiment of the invention, the two piece shoe has first and second segments that interlock to hold the two segments together as they slid along the track. In this embodiment, either the second segment is taller than the first segment or the sash arm includes an off-set portion that rises over the second segment and lifts the sash arm when it contacts the shipping block segment. Thus, the weight of the sash is transfer from the portion of a shoe including the roller to the shipping block segment. 
         [0016]    In another embodiment of the invention, the shipping block segment is located within and surrounded by the first segment. In this embodiment, the first segment houses the roller while the second segment is located within the first segment in an opening. The second segment may be taller than the first segment. The sash arm rides over the second shipping block segment and is lifted as it rides over the top of the second segment thereby transferring the load from the roller to the shipping block segment. Alternately, the shipping block segment may be of equal height with the first segment that houses the roller but a protrusion extending downwardly from the shipping arm bares on the shipping block segment to carry the weight of the sash through the sash arm when the window is in the closed position, thus acting as a shipping block. 
         [0017]    A window can be equipped with an upper hinge that operates in the same manner. Any upward loads encountered during shipping are thus transmitted from the sash into the frame during shipping, protecting the upper roller as well. While the majority of the friction forces in the sliding shoe are vertical, in one embodiment of the invention, one or more additional rollers can also be added perpendicular to the first roller to also reduce the friction forces in the horizontal plane, allowing even heavier sash weights without increasing the loads places on the operator mechanism. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the following drawings, in which: 
           [0019]      FIG. 1  is a perspective view of a casement window hinge according to an embodiment of the invention, with the hinge positioned in an open position; 
           [0020]      FIG. 2  is another perspective view of the hinge of  FIG. 1 ; 
           [0021]      FIG. 3  is a perspective view of the hinge of  FIG. 1  in the closed position; 
           [0022]      FIG. 4  is a fragmentary perspective view of a portion of the shoe, track and sash arm of the hinge of  FIG. 1 ; 
           [0023]      FIG. 5  is a side elevation view of the hinge portion depicted in  FIG. 4 ; 
           [0024]      FIG. 6  is a perspective view of the underside of the shoe of the hinge of  FIG. 1 ; 
           [0025]      FIG. 7  is a perspective view of a casement window hinge according to an embodiment of the invention, with the hinge positioned in a partially open position; 
           [0026]      FIG. 8  is an end elevation view of the hinge depicted in  FIG. 7 ; 
           [0027]      FIG. 9  is a perspective view of the hinge of  FIG. 7 ; 
           [0028]      FIG. 10  is an elevation view of a casement window according to an embodiment of the invention; 
           [0029]      FIG. 11  is a schematic plan view of another embodiment according to the invention. 
           [0030]      FIG. 12  is a perspective view of a hinge assembly in accordance with an embodiment of the invention in the open position. 
           [0031]      FIG. 13  is a perspective view of the hinge assembly of  FIG. 12  in the closed position. 
           [0032]      FIG. 14  is a plan view of a shoe according to an embodiment of the invention. 
           [0033]      FIG. 15  is an elevational view of the shoe depicted in  FIG. 14 . 
           [0034]      FIG. 16  is a plan view of a shoe according to an embodiment of the invention. 
           [0035]      FIG. 17  is an elevational view of the shoe depicted in  FIG. 16 . 
           [0036]      FIG. 18  is a plan view of a shoe according to an embodiment of the invention. 
           [0037]      FIG. 19  is an elevational view of the shoe depicted in  FIG. 18 . 
           [0038]      FIG. 20  is an elevational view of the shoe depicted in  FIGS. 18 and 19 , incorporated into a hinge assembly. 
       
    
    
       [0039]    While the present invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0040]    A casement window hinge  10  according to an embodiment of the invention is depicted in  FIGS. 1-10 . Referring particularly to  FIGS. 1 ,  2  and  4  hinge  10  generally includes track assembly  12 , sash arm  14 , and connecting arm  16 . Track assembly  12  generally includes track  18  and shoe  20 . Track  18  is generally L-shaped and has horizontal portion  22  and vertical portion  24 . In the depicted embodiment, vertical portion  24  defines u-shaped retaining portion  26  at upper edge  28 . 
         [0041]    Referring to  FIGS. 3-6 , shoe  20  generally includes body portion  30 , roller  32 , and axle  34 . Body portion  30  defines upwardly-projecting guide lip  36 . Top surface  38  is substantially planar. Bottom surface  40 , however, is shaped as a rocker with first portion  42  being parallel with top surface  38  and second portion  44  tapering slightly upward from apex  46 . Roller  32  is received on axle  34 , and the ends  48  of axle  34  are received in notches  50  such that roller  32  rotates on axle  34  within cavity  51  defined in body portion  30 . Guide lip  36  is engaged in u-shaped retaining portion  26  of track  18 . Sash arm  14  is pivotally attached to shoe  20  at pivot  52 . 
         [0042]    Sash arm  14  defines downwardly projecting ramp  54  adjacent outer edge  56 . Ramp  54  is registered with second portion  44  of bottom surface  40  of shoe  20 . 
         [0043]    Connecting arm  16  is pivotally attached to track  18  at pivot  58  and pivotally attached to sash arm  14  at pivot  60 . 
         [0044]    Referring to  FIGS. 8 and 9 , horizontal portion  22  of track  18  presents upper surface  62 . Bottom surface  40  of shoe  20  confronts upper surface  62  as does roller  32 . Ramp  54  confronts inner end  64  of top surface  38  of shoe  20  when sash arm  14  is aligned parallel to track  18 . 
         [0045]    Referring to  FIG. 10 , hinge  10  in accordance with the invention can be installed in casement window assembly  100 . Casement window assembly  100  includes frame  102  surrounding opening  104  and sash  106 . Typically, a first hinge  10  and a second hinge  10  will couple sash  106  to frame  102 . First and second hinges  10  will include a right handed hinge  10  and a left handed hinge  10 . In one embodiment of the invention, a first track  18  is secured to top edge  108  of frame  102  and a second track  18  is secured to bottom edge  110  of frame  102 . First sash arm  14  is secured to top surface  114  of sash  106  and second sash arm  14  is secured to bottom surface  114  of sash  106 . 
         [0046]    In use, typically two hinges  10  are used in a casement window assembly  100  to operably couple sash  106  with frame  102 . One track assembly  12  is fixed along top  108  edge of frame  102 . Another track assembly  12  is fixed along bottom  110  edge of frame  102 . Sash arm  14  of one hinge  10  is attached to the top surface  112  of sash  106 . Sash arm  14  of another hinge  10  is attached to the bottom surface  114  of sash  106 . 
         [0047]    Referring to  FIG. 11 , another embodiment of hinge  10  is schematically depicted. Here, hinge  10  is structured similarly to embodiments described above and in addition includes at least one vertically oriented roller  66 . The depicted embodiment includes two vertically oriented rollers  66 . Vertically oriented roller  66  is positioned in vertically oriented roller cavity  68  with axle  70  being supported by body portion  30  of shoe  20 . 
         [0048]    Vertically oriented roller  66  confronts vertical portion  24  of track  18  or u-shaped retaining portion  26  or both. 
         [0049]    Referring to  FIGS. 12 through 15 , another embodiment of hinge  10 , in accordance with the invention is depicted. The depicted embodiment of hinge  10  includes track assembly  12 , including sash arm  14 , connecting arm  16  and track  18 . In the depicted embodiment, two segment shoe  116  includes roller segment  118 , shipping block segment  120  and coupling portion  122 . Roller segment  118  generally includes roller  32  and axle  34  similar to other described embodiments. Roller segment  118  may include multiple rollers  32  and axles  34 . Roller segment  118 , shipping block segment  120  and coupling portion  122  may be molded as a unit or may be formed of separate parts. Shipping block segment  120  is generally slightly thicker or taller than roller segment  118 . Coupling segment  122  may be formed of a flexible material to allow some flexibility or resiliency between roller segment  118  and shipping segment  120  or may be structured to flex. 
         [0050]    In this embodiment of the invention, sash arm  14  may include offset  124 . Offset  124  is a thickened or outwardly projecting portion of sash arm  14  that projects outwardly in the direction of shipping block segment  120 . Roller segment  118  and shipping block segment  120  slide on track  18  in a coupled fashion. 
         [0051]    Coupling segment  122  may have a sigmoid structure  126  as depicted in  FIGS. 12 and 14 . 
         [0052]    Referring to  FIGS. 16 and 17 , another embodiment of two segment shoe  116  is depicted. In this embodiment, two segment shoe  116  includes roller segment  128  and interlock segment  130 . Roller segment  128  includes roller  32  and axle  34  as in other embodiments disclosed herein. Roller segment  128  also defines interlock recess  132 . Interlock segment  130  includes body portion  134  and lobe  136 . As can be seen in  FIG. 16 , interlock recess  132  and lobe  136  are shaped to be complementary and to engage each other. The arrangement can be reversed as well with roller segment  128  presenting lobe  136  and interlock segment defining interlock recess  132 . As depicted in  FIG. 17 , interlock segment  130  is slightly taller or thicker than roller segment  128 . In this embodiment, sash arm  14  again may present offset  124  which extends toward body portion  134  of interlock segment  130 . 
         [0053]    Referring to  FIGS. 18 ,  19  and  20 , another embodiment of two segment shoe  116  is depicted. In the depicted embodiment, two segment shoe  116  includes roller segment  138  and captured shipping block segment  140 . In this embodiment again, roller segment  138  includes roller  32  and axle  34 . Roller segment  138  is generally similar to shoe  20  in its other structural features. Roller segment  138  further defines capture bore  142 . While capture bore  142  is depicted as circularly cylindrical in  FIG. 18 , it may take any geometrical shape that permits horizontal capture of captured shipping block segment  140  with relatively free vertical movement. Captured shipping block segment  140  fits into capture bore  142 . Captured shipping block segment  140  is slightly taller or thicker than roller segment  138 . Captured shipping block segment  140  is free to move vertically within roller segment  138  to at least some degree. Captured shipping block segment  140  presents upper surface  144  which can engage connecting arm  16 . 
         [0054]    Optionally, in this embodiment, connecting arm  16  may include offset  124  extending toward captured shipping block segment  140 . 
         [0055]    In another embodiment of the invention, captured shipping block segment  140  may be of similar height to roller segment  138  while connecting arm  16  includes off-set  124  positioned to engage captured shipping block segment  140  when the window sash is in the closed position. 
         [0056]    In operation, when sash  106  is in an open position as depicted in  FIG. 10 , roller  32  rests on upper surface  62  of horizontal portion  22  of track  18 . As sash  106  is repositioned using an operator or manually, roller  32  rolls over upper surface  62  of horizontal portion  22 , thereby reducing friction between shoe  20  and track  18  as compared to the sliding friction of shoe  20  over track  18  if roller  32  was not present. 
         [0057]    When sash  106  is near to being closed, ramp  54  begins to engage top surface  38  of shoe  20  as sash  106  swings inward toward frame  102  and urges inner end  64  of shoe  20  downward. As shoe  20  rocks on apex  46 , apex  46  acts as a fulcrum and roller  32  is lifted away from track  18 , while second portion  44  of shoe  20  moves downward into engagement with upper surface  62 . When sash  106  is in the fully closed position, roller  32  may be entirely clear of track  18  while second portion  44  rests on track  18 . When sash  106  is opened, shoe  20  rocks back on apex  46  as ramp  54  clears top surface  38 , enabling roller  32  to engage track  18  and lifting second portion  44  clear of track  18 . 
         [0058]    Referring to  FIG. 11 , in other embodiments of hinge  10 , friction of shoe  20  with track  18  can be further decreased and the overall load bearing capacity of hinge  10  can be further increased by vertically oriented roller  66  between shoe  20  and vertical portion  24  of track  18  or u-shaped retaining portion  26 . At least one vertically oriented roller  66  rolls against track  18  when sash  106  is being opened or closed. 
         [0059]    Referring to  FIGS. 12-15 , in this embodiment roller segment  118  and shipping block segment  120  are joined by coupling segment  122 . When the window is in the open position or in the process of opening or closing, shipping block segment  120  and roller segment  118  slide together on track  18 . When the window is nearly closed, shipping block segment  120  engages sash arm  14  and offset  124 , if present. The additional height of shipping block segment  120  and the extension of offset  124  toward shipping block segment  120  create a bearing relationship between frame  102  and sash  106  of casement window assembly  100  via sash arm  14  thus, removing any impact or handling loads from the hardware of casement window assembly  100  by providing an alternate path for those loads. 
         [0060]    Referring to  FIGS. 16 and 17 , again when casement window assembly  100  is closed or nearly closed interlock segment  130  engages sash arm  14  and off-set  124 , if present, transmitting loads from frame  102  to sash  106  and acting as a shipping block. Lobe  136  of body portion  134  engages interlock recess  132  to couple interlock segment  130  to roller segment  128  when casement window assembly  100  is in the open position or moving between the open and close position but permits vertical movement of interlock segment  130  relative to roller segment  128 . 
         [0061]    Referring to  FIGS. 18-20 , captured shipping block segment  140  is free to move vertically at least to a small degree within capture bore  142  of roller segment  138 . When casement window assembly  100  is closed or nearly closed, sash arm  14  and off-set  124 , if present, engage captured shipping block segment  140  which may be slightly taller than roller segment  138 . Thus, loads are transferred via captured shipping block segment  140  from frame  102  to sash  106  thus allowing captured shipping block segment  140  to act as a shipping block and prevent damage to the hardware of casement window assembly  100 . 
         [0062]    Various modifications to the invention may be apparent to one of skill in the art upon reading this disclosure. For example, persons of ordinary skill in the relevant art will recognize that the various features described for the different embodiments of the invention can be suitably combined, un-combined, and re-combined with other features, alone, or in different combinations, according to the spirit of the invention. Likewise, the various features described above should all be regarded as example embodiments, rather than limitations to the scope or spirit of the invention. Therefore, the above is not contemplated to limit the scope of the present invention. 
         [0063]    For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.