Patent Publication Number: US-6662512-B2

Title: Two-piece mullion reinforcement

Description:
This is a continuation-in-part of copending patent application Ser. No. 09/607,762, titled TWO-PIECE MULLION REINFORCEMENT, filed Jun. 30, 2000, and now issued as U.S. Pat. No. 6,360,498. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to window assemblies, and more particularly to a reinforcing mullion that enhances structural rigidity while allowing for field construction of multiple window assemblies. 
     BACKGROUND OF THE INVENTION 
     Window frames traditionally have been made from wood or metal or various combinations of wood and metal. In recent years, windows formed with hollow metal or polymer frames have become popular, due to their improved thermal properties, lower cost and relative ease of manufacture, assembly and installation compared with traditional wood and metal windows. Such window assemblies may be limited in size by the requirement that they withstand design wind-loads as established by local building codes and ordinances. Another factor limiting the allowable size of multiple window assemblies is the fact that such assemblies are very often difficult to transport, handle, and install. 
     Windows made from various combinations of polymer and metal components are known in the prior art. For example, U.S. Pat. No. 5,435,106 discloses a window assembly including adjacent first and second windows and a reinforcing mullion connecting the windows. The mullion comprises hollow polymeric first and second lineals and a single metal reinforcing bar fastened between the lineals. Interior and exterior face caps that are attached to the lineals span a gap between them. A steel plate, two high strength steel bolts or posts, and several wood screws are provided for connecting an end portion of the metal reinforcing bar to a support structure surrounding the window opening in the building. The mullion adds rigidity to the assembly, thereby allowing for an increase in its allowable size. Various other prior art designs have also provided similar structures to add rigidity to a window assembly, e.g., U.S. Pat. Nos.: 6,014,846; 5,937,597; and 4,981,001. 
     These and other prior art windows generally suffer from one or more disadvantages making them less than entirely suitable. For example, as windows of these types are arranged in multiple window assemblies, the assemblies become quite large and heavy. As a result, these prior art window assemblies are difficult to handle, and often do not lend themselves to field installation. Accordingly, there is a need to provide windows with field assemblable reinforcements so that they are able to meet design standards economically, when several such windows are combined into a unitary assembly, and to be easily and economically assembled together in the field or factory. 
     SUMMARY OF THE INVENTION 
     The present invention provides a two-piece mullion reinforcement for use in forming an assembly of windows. In one embodiment, a first member that is fastenable to a portion of a first window frame, includes at least one piloting tab that extends along and projects outwardly from a surface of the first member. A second member that is likewise fastenable to a portion of a second window frame, includes at least one pilot receptacle that is formed on a surface of the second member. Advantageously, the pilot tab and pilot receptacle comprise mutually complementary profiles so as to be engagable with one another when the first window frame is assembled to the second window frame. In another embodiment, the first member includes a first portion of at least one latch and the second member includes a second portion of the at least one latch that is complementary to the first portion so that when the first window frame is assembled to the second window frame the first member and the second member cooperate to form at least one latch. A window assembly is also provide including adjacent first and second windows each having a frame and being connected by a two-piece mullion reinforcement according to the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and other features and advantages of the present invention will be more fully disclosed in, or rendered obvious by, the following detailed description of the preferred embodiment of the invention, which is to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein: 
     FIG. 1 is a front elevational view of a window assembly made in accordance with the present invention viewed from the interior of a building; 
     FIG. 2 is a top cross-sectional view of a two-piece mullion reinforcement formed according to the present invention, as taken along section line  2 — 2  in FIG. 1; 
     FIG. 3 is a broken-away perspective view of the two-piece mullion reinforcement of the present invention, as assembled, but with the window frame removed for clarity of illustration; 
     FIG. 4 is an exploded and enlarged top view of the cross-section of the two-piece mullion reinforcement shown in FIG. 2; 
     FIG. 5 is a perspective view of male reinforcement member; 
     FIG. 6 is a perspective view of female reinforcement member; 
     FIG. 7 is a top cross-sectional view of a thermal barrier lock; 
     FIG. 8 is a top cross-sectional view of a cover; 
     FIG. 9 is a top cross-sectional view of an exterior cover lock; 
     FIG. 10 is a top cross-sectional view, similar to that shown in FIG. 2, but showing the male and female mullion reinforcement members assembled to the frame and engaged with one another just prior to engagement of the inner and outer locks and cap; and 
     FIG. 11 is a side elevational view of the two-piece mullion reinforcement, as taken along section line  11 — 11  in FIG. 1, and showing a portion of an L-bracket in phantom; and 
     FIGS. 12-16 are each a top cross-sectional view, partially in phantom and similar in perspective to FIG. 2, of a variety of alternative two-piece mullion reinforcements formed according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     This description of preferred embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. The drawing figures are not necessarily to scale and certain features of the invention may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness. In the description, relative terms such as “horizontal,” “vertical,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms including “inwardly” versus “outwardly,” “longitudinal” versus “lateral” and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term “operatively connected” is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship. In the claims, means-plus-function clauses are intended to cover the structures described, suggested, or rendered obvious by the written description or drawings for performing the recited function, including not only structural equivalents but also equivalent structures. 
     Referring to FIG. 1, the windows forming a portion of the assemblies discussed in this detailed description are often made up of two or more adjacent discrete windows, and are preferably generally rectangular, with each including elongated stiles, a sill and a rail. Frames of the windows are preferably made from hollow, rigid extrusions that are formed from light weight metals or polymers. For example, window assembly  5  includes two laterally adjacent window units  3 , 4  having hollow frames  6 , 7  supporting glass window panes  9 , 10 , respectively. Frames  6 , 7  include inner jambs  13 , 14  and outer jambs  16 , 17  both connecting bottom sills  20 , 21  to heads or rails  24 , 25 , respectively. Frames  6 , 7  may also include a nailing flange  27 . A centrally located mullion  30  interconnects frames  6 , 7  to form window assembly  5 , and to improve structural rigidity. 
     It will be understood that the present invention is in no way limited to a two window assembly, and may be advantageously used in multiple window assemblies. Also, the two-piece mullion reinforcement of the present invention is suitable for use with other types of window assemblies, including but not limited to, sliding sash windows, picture windows, awning windows, jalousie windows, tilt and turn windows and patio doors of all types. 
     Referring now to FIGS. 2-5 and  9 - 10 , the present invention provides a field mulling apparatus comprising a male mullion reinforcement member  40  (FIG. 5) and a female mullion reinforcement member  41  (FIG.  6 ). The two mullion reinforcement members  40 , 41  are adapted to be mounted upon a portion of inner jamb  13 , 14  of frames  6 , 7  so as to allow for the field construction of window assembly  5 , and to securely hold a thermal barrier  42 , an exterior cover  43 , and an interior cover  47  in place at the junction between windows  3 , 4 . More particularly, mullion reinforcement members  40 , 41  are each elongate plank-like structural elements, having a selectively formed transverse cross-sectional profile (best seen in FIGS. 3,  5  and  6 ). Preferably, mullion reinforcement members  40 , 41  comprise a metal, such as an aluminum alloy or steel, or a combination of aluminum alloy and steel, or may comprise other metals, a structural polymer, or a fiber glass or carbon fiber reinforced composite material of the type well known in the art. Each mullion reinforcement member  40 , 41  has a length that is at least similar to the length of inner jambs  13 , 14  or outer jambs  16 , 17  of frames  6 , 7 . Mullion reinforcement members  40 , 41  are often extruded in over-sized lengths, e.g., fourteen foot lengths, and cut down to fit a wide variety of windows. 
     Referring to FIGS. 3 and 4, the transverse profile of male mullion reinforcement member  40  is formed to include a first half  50  of a thermal barrier latch  48 , a first piloting tab  51 , a central portion  52 , a second piloting tab  53 , a frame lock  54 , and a first half  55  of an exterior cover latch  49 . The first half  50  of thermal barrier latch  48  is essentially a cantilevered beam formed on a lateral edge of male mullion reinforcement member  40 , that narrows to form a chamfered tip  58 . Parallel rows of teeth  60  are formed on the inner side of first half  50  of thermal barrier latch  48 , adjacent to chamfered tip  58 , and extend toward a shoulder portion  59  that is formed in spaced relation to chamfered tip  58 . 
     First piloting tab  51  and second piloting tab  53  project outwardly in substantially perpendicular relation to the inner side of male mullion reinforcement member  40 , with central portion  52  positioned between them. First piloting tab  51  is positioned adjacent to shoulder  59  and second piloting tab  53  is positioned adjacent to frame lock  54 . First and second piloting tabs  51 , 53  are substantially parallel to one another, and may have any one of a variety of cross-sectional shapes including rectilinear, polygonal, circular, elliptical, etc. Central portion  52  extends between first and second piloting tabs  51 , 53 , and includes through-holes  61  that are sized to receive fastener  62 , e.g., screws, nails, or the like. 
     Frame lock  54  projects outwardly from an outer side of male mullion reinforcement member  40 , and includes a pair of spaced apart feet  63  and a longitudinally oriented bore  65  that opens at a terminal end of male mullion reinforcement member  40 . Second through-bores  66  are defined in frame lock  54 , and communicate between the inner side and the outer side of male mullion reinforcement member  40 . First half  55  of exterior cover latch  49  projects from a side surface of frame lock  54  and includes a locking beam  68  and a catch  70 . Locking beam  68  comprises a cantilevered beam, which may include a locating leg  69  projecting outwardly from its free end (FIG.  15 ). Catch  70  preferably comprises a substantially triangular cross-sectional shape, including sloping surfaces  72 . Of course, other cross-sectional shapes may be utilized as long as they provide structure for engaging exterior cover  43 . A stem  73  projects from a portion of catch  70  so as to attach it to a portion of frame lock  54 . In this way, a pair of shoulders  75  are formed adjacent to the sides of stem  73 . 
     Referring to FIG. 6, the transverse profile of female mullion reinforcement member  41  is substantially similar to that of male mullion reinforcement member  40 , and includes a second half  80  of thermal barrier latch  48 , a first piloting tab receptacle  81 , a central portion  82 , a second piloting tab receptacle  83 , a frame lock  84 , and a second half  85  of exterior cover latch  49 . More particularly, second half  80  of thermal barrier latch  48  is essentially a cantilevered beam formed on a lateral edge of female mullion reinforcement member  41 , that narrows to form a chamfered tip  88 , and is complementary to first half  50 , i.e., completes the structure of thermal barrier latch  48 . Parallel rows of teeth  90  are formed on the inner side of second half  80  of thermal barrier latch  48 , adjacent to chambered tip  88 , and extend toward a shoulder portion  89  that is formed in spaced relation to tip  88 . 
     First piloting tab receptacle  81  and second piloting tab receptacle  83  open outwardly in substantially perpendicular relation to the inner side of female mullion reinforcement member  41 , with central portion  82  positioned between them. First piloting tab receptacle  81  is positioned adjacent to shoulder  89  and second piloting tab receptacle  83  is positioned adjacent to frame lock  84 . First and second piloting tab receptacles  81 , 83  are substantially parallel to one another, and may have any one of a variety of cross-sectional shapes including rectilinear, polygonal, circular, elliptical, etc., as long as their shape corresponds to, and is complementary to, the cross-sectional shape of first and second piloting tabs  51 , 53 , respectively. Central portion  82  extends between first and second piloting tab receptacles  81 , 83 , and includes through-holes  91  that are sized to receive fasteners  62 . 
     Frame lock  84  projects outwardly from the outer side of female mullion reinforcement member  41 , and includes a pair of spaced apart feet  93  and a longitudinally oriented bore  95  that opens at a terminal end of female mullion reinforcement member  41 . Second through-bores  96  are defined in frame lock  84 , and communicate between the inner side and the outer side of female mullion reinforcement member  41 . Second half  85  of exterior cover latch  49  projects from a side surface of frame lock  84 , comprises a cantilevered beam, and is complementary to first half  55 , i.e., completes the structure of exterior latch  49 . 
     Referring to FIGS. 7,  8 , and  9 , to complete window assembly  5  thermal barrier  42 , exterior cover  43 , and interior cover  47  are mounted to mullion reinforcement members  40 , 41  and onto a portion of inner jamb  13 , 14  of frames  6 , 7 . More particularly, thermal barrier  42  is an elongate structural element typically formed or extruded from one of the well known engineering polymers that are often used in the construction trade, e.g., polyvinyl chloride or similar compounds. Of course, thermal barrier  42  may be formed from fiber glass or carbon fiber reinforced composite materials or the like and of type well known in the art. When applied to window assembly  5 , thermal barrier  42  has a length that is at least similar to the length of inner jambs  13 , 14  or outer jambs  16 , 17  of frames  6 , 7 . When manufactured, thermal barrier  42  is often extruded in over-sized lengths, e.g., fourteen foot lengths, and cut down to fit a wide variety of windows. 
     Thermal barrier  42  includes an insulating channel  110 , an inner catch  112 , an outer catch  113 , and insulating flanges  115 . More particularly, insulating channel  110  comprises a web  118  and spaced apart flanges  120 . Inner catch  112  projects from web  118  so as to be located between flanges  120 , and has a substantially triangular cross-sectional shape, including sloping surfaces  122 . A stem  123  projects from web  118  so as to attach inner catch  112  to insulating channel  110 . In this way, at least a pair of shoulders  125  are formed adjacent to the sides of stem  123  and spaced away from web  118 . 
     Outer catch  113  projects outwardly and away from web  118  and flanges  120 , and also preferably has a substantially triangular or conical cross-sectional shape, including sloping outer surfaces  132 . Of course, other cross-sectional shapes may be utilized as long as they provide structure for engaging interior cover  47 . A central recess  129  is formed in outer catch  113  to provide for resilience when mating with a corresponding latch portion of interior cover  47 . A stem  133  projects from web  118  so as to attach outer catch  113  to insulating channel  110 . In this way, at least a pair of shoulders  135  are formed adjacent to the sides of stem  133  and spaced away from web  118 . Insulating flanges  115  project outwardly from the intersection between web  118  and flanges  120  in substantially parallel relation to web  118 . 
     Referring to FIGS. 8 and 9, exterior cover  43  includes an insulating channel  140  and insulating flanges  141 . More particularly, insulating channel  140  comprises a web  142  and spaced apart flanges  144 , wherein flanges  144  include inwardly projecting shoulder  145  positioned at their terminal ends. Insulating flanges  141  project outwardly from the intersection between web  142  and flanges  144 , in sloping relation to web  142 . Interior cover  47  comprises a channel-shaped cross-section having a web  150  and spaced apart flanges  152  positioned at the ends of web  150 . A pair of spaced apart latching flanges  155  project outwardly from web  150  in substantially parallel relation to one another. Each latching flange  155  includes inwardly projecting shoulders  158  positioned at their terminal ends. 
     The present invention is used to form a window assembly  5  in the following manner. Referring to FIGS. 2,  4 , and  10 , male and female mullion reinforcing members  40 , 41  are first fastened to corresponding portions of frames  13 , 14 . More particularly, male mullion reinforcing member  40  is oriented so that frame lock  54  is positioned in confronting aligned relation to a corresponding recessed feature of frame  13  (shown generally at reference numeral  200  in the figures). Once in this position, male mullion reinforcement member  40  is moved toward frame  13  so that frame lock  54  enters recess  200  until feet  63  engage a portion of frame  13 . Fasteners  62  are then inserted through bores  61  and  66  so as to fasten male mullion reinforcement member  40  to frame  13 . A similar procedure is followed in attaching female mullion reinforcement member  41  to frame  14 . More particularly, frame lock  84  is positioned in confronting aligned relation with corresponding recess  205  of frame  14 , and female mullion reinforcement member  41  is moved toward frame  14  until feet  93  engage a portion of frame  14 . Fasteners  62  are then positioned through bores  91  and  96  of female mullion reinforcement member  41  so as to attach it to frame  14 . It should be noted that mullion reinforcement members  40 , 41  are designed such that they can be interchanged, left to right, as viewed in FIG. 4, without deviation from the present invention. It should also be noted that mullion reinforcement members  40 , 41  may be installed on frames  13 , 14  at the factory during a portion of the window manufacturing process or, at the construction site by the window assembly installers. 
     Once frames  13 , 14  have mullion reinforcement members  40 , 41  fastened to their side surfaces, a window assembly  5  may be formed. More particularly, frames  13 , 14  are aligned such that first and second piloting tabs  51 , 53  are in confronting aligned relation with first and second piloting tab receptacles  81 , 83 . Once in this position, frames  13 , 14  are moved toward one another until first and second piloting tabs  51 , 53  are received within first and second piloting tab receptacles  81 , 83 . This arrangement of pilots and pilot receptacles provides for proper registration and mating of adjacent individual windows so as to form a window assembly. 
     As mullion reinforcement members  40 , 41  are engaged, the complementary portions of thermal barrier latch  48  and exterior cover latch  49 , that are formed on mullion reinforcement members  40 , 41 , are positioned in latch completing relationship to one another so as to form latches  48  and  49  on window assembly  5 . 
     Referring to FIG. 10, with male and female mullion reinforcement members  40 ,  41  engaged and forming a mullion between windows  3 , 4 , thermal barrier  42 , exterior cover  43 , and interior cover  47  may be assembled to mullion reinforcement member  40 , 41  so as to complete window assembly  5 . More particularly, thermal barrier  42  is oriented so that inner catch  112  is positioned in confronting aligned relation with thermal barrier latch  48 . Once in this position, thermal barrier  42  is moved toward window assembly  5  so that inner catch  112  moves between first and second halves  50 , 80  of thermal barrier latch  48 . As this occurs, teeth  60  engage shoulders  125  so as to firmly retain thermal barrier  42  on mullion reinforcement members  40 , 41 . At the same time, flanges  120  slip between first and second halves  50 , 80  and a portion of frames  13 , 14  so as to isolate mullion reinforcement members  40 , 41  from frames  13 , 14 . Flanges  115  of thermal barrier  42  engage the outer surfaces of frames  13 , 14  once inner catch  112  is fully engaged by thermal barrier latch  48 . It will be understood that thermal barrier  42  provides the required insulative barrier between the intersection of windows  3 , 4  and the surrounding environment. 
     With thermal barrier  42  in place and engaged with mullion reinforcement members  40 ,  41 , interior cover  47  may be fastened to thermal barrier  42 . More particularly, interior cover  47  is first oriented so that latching flanges  155  are positioned in confronting aligned relation with outer catch  113  and thermal barrier  42 . Once in this position, interior cover  47  is moved toward thermal barrier  42  until shoulders  158  of flanges  155  engage shoulders  135  of outer catch  113  so as to firmly fasten interior cover  47  to thermal barrier  42 . Exterior cover  43  is similarly fastened to exterior cover latch  49  by positioning insulating channel  140  in confronting aligned relation with catch  70  of exterior latch  49 . Once in this position, exterior cover  43  is moved toward catch  70  so that flanges  144  slide along surface  72  of catch  70  until shoulders  145  engage corresponding shoulder  75  of catch  70 . 
     Referring to FIG. 11, window assembly  5  is fastened to a portion of the building into which it is being installed by attaching a bracket  220  to either or both mullion reinforcement members  40 , 41 , and inserting a fastener  62  through a corresponding hole in bracket  220  and engaging either of bores  65  or  95 . 
     Referring to FIGS. 12-16, the two-piece field mullion of the present invention may be modified in a number of ways without departing from the scope or spirit of the present invention. For example, catch  70  may be split into halves  170 , 171  that are formed on male mullion reinforcement member  40  and female mullion reinforcement member  41 , respectively, as shown in FIG.  12 . Halves  170 , 171  of male mullion reinforcement member  40  and female mullion reinforcement member  41  each comprise a substantially triangular cross-sectional shape, including sloping surfaces  172 . Of course, other cross-sectional shapes may be utilized as long as they provide structure for engaging exterior cover  43 . A stem  173  projects from a portion of each half  170 , 171  so as to attach each half to an inner portion of frame locks  54 , 84 , respectively. In this way, a pair of shoulders  175  are formed adjacent to the sides of stems  173 . 
     In addition, secondary frame locks  154 , 184  may be provided that project outwardly from the outer side of male mullion reinforcement member  40  and female mullion reinforcement member  41  (FIGS.  13  and  14 ). Secondary frame locks  154 , 184  may be used when frames  13 , 14  include upper recesses  206 , 207  in addition to lower recesses  200 , 205 . Frame locks  154 , 184  each define a recess  168  that is sized and shaped to accept spaced apart flanges  120  of thermal barrier  42 . 
     Referring to FIG. 15, a pair of U-shaped catches  147  combine to form a thermal barrier latch  148  on the end of an assembled male mullion reinforcement member  40  and female mullion reinforcement member  41 . Each U-shaped catch  147  comprises two cantilevered beams  149 , 151 . Parallel rows of teeth  60  are formed on the inner side of each first cantilever  149  so as to be arranged in confronting spaced relation to one another. In this way, when inner catch  112  engages teeth  60 , first cantilevers  149  deflect outwardly toward frames  13 , 14 , respectively. Secondary cantilevers  151  extend from an end of each first cantilever  149  so that when thermal barrier  42  is mounted to thermal barrier latch  148 , spaced apart flanges  120  engage and deflect secondary cantilevers  151  so as to provide further sealing engagement between thermal barrier  42 , frames  13 , 14 , and male mullion reinforcement member  40  and female mullion reinforcement member  41 . 
     Referring to FIG. 16, in some windows recesses (e.g., recesses  200 ,  205 ,  206 ,  207 ) are not provided in the inner surfaces of frames  13 , 14 . In these instances, frame latches are provided adjacent to catch  70  so as to help retain male mullion reinforcement member  40  and female mullion reinforcement member  41  in place between frames  13 , 14 . Each frame latch comprises a cantilevered beam  194  and an outwardly facing hook  196 . When assembled to frames  13 , 14 , hooks  196  engages tabs  19  located at the end of the inner surfaces of male mullion reinforcement member  40  and female mullion reinforcement member  41 . 
     It is to be understood that the present invention is by no means limited only to the particular constructions herein disclosed and shown in the drawings, but also comprises any modifications or equivalents within the scope of the claims.