Patent Publication Number: US-2018038144-A1

Title: Window framing system with three main extrusions

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of pending U.S. provisional patent application No. 62/371,654 filed on Aug. 5, 2016, which is hereby incorporated by reference in its entirety, and further claims the benefit of pending U.S. provisional patent application No. 62/421,228 filed on Nov. 12, 2016, which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     The present invention relates to devices and methods for economically constructing energy-efficient windows using only three main extrusions. All window types may be constructed using only the three main extrusions. 
     Existing window systems are typically designed with each window type (single-hung and double-hung vertical windows, horizontal sliders, and fixed) as a separate family of extrusions. And, for each window type there is a main frame, a sash frame, and for vertical or horizontal sliding windows also an interlock mechanism. Finally, there may be other miscellaneous extrusions and hardware. 
     The traditional window design typically requires seven or more separately designed extrusions for construction of the main and sash framing for each window type. When manufacturing a complete window system for vertical sliders, horizontal sliders, and fixed windows, the number of extrusions maybe as many as 16 or 17. As a result, the tooling costs for new systems are quite high because separate tooling is needed for each of the multiple extrusions for each window type. Therefore, many manufacturers have been reluctant to explore new materials that avoid the defects and issues with existing materials. 
     Existing materials include wood, vinyl, and aluminum. Each of these has issues. For example, aluminum window frames allow excessive transmission of heat and cold; wood window frames require high maintenance requirements; and vinyl window frames lack the ability to withstand weather extremes. 
     Another factor in the expense of window manufacturing is the cost of compliance with increasingly strict energy efficiency standards. Window manufacturers typically use materials such as wood, vinyl, and aluminum in an attempt to meet the energy efficiency standards set by government agencies. These government standards have become stricter over time, and in many cases the standards cannot be met using current designs and materials. While newer materials have been developed, the cost of retooling has discouraged their adoption by the industry. Faced with these challenges, manufacturers and architects resort to other, also expensive, solutions such as increased insulation, and coated glass. 
     The system described herein addresses these problems by greatly simplifying the manufacture of the basic frame and sash combination used in nearly all conventional windows. 
     Shortcomings in Current Systems: Three primary challenges must be met in order to meet current and anticipated regulatory and structural requirements. 
     U-values: The rate of heat loss in a window system is measured by its U-value. 
     The lower the U-value, the greater the window&#39;s resistance to heat flow and the greater its insulating properties. The fenestration industry has struggled to find a way to lower the U-value of its products. Thermo-plastic (e.g. vinyl) and wood materials are used in an attempt to do this. However, these materials are of limited effectiveness because of strength limitations under heavy loads. Aluminum has been used for many years to provide the strength required in windy areas and tall buildings. However, aluminum fenestration products have been unable to achieve the lower energy standards because of their high U-values, i.e. they are relatively efficient conductors of heat and cold. 
     Thermal expansion: Different materials expand (or contract) at different rates as temperatures rise or fall. The higher the Coefficient of Thermal Expansion (COTE), the less desirable is the material in question. It is also undesirable for a window assembly to utilize different materials with widely varying COTEs. The closer the COTEs are, the better the window system performs. For example, the Coefficient of Thermal Expansion (inch/inch/degree F) of Polyvinyl Chloride (PVC) is 0.000071 inch/inch/degree F, aluminum is 0.0000123 inch/inch/degree F and glass is 0.000005 inch/inch/degree F. Not only does Polyvinyl Chloride (PVC) expand and contract up to 14 times that of the other mentioned materials, it also loses its ability to support heavy loads as temperatures rise. This makes PVC, or vinyl, a highly unlikely choice for larger projects in areas with variable ambient temperatures. 
     Modulus of Elasticity: This is a measure of the strength of a given material when under stress from factors like wind, seismic events, settlement, surrounding structures, etc. The modulus of elasticity of thermal-plastics is 0.3 lbs/inch squared, while for aluminum it is 10,000,000 lbs/inch squared. Thus, aluminum is far stronger than either wood or vinyl. But, aluminum is less desirable for the fenestration industry in both U-values and thermal expansion. 
     SUMMARY 
     The invention comprises a window system for economically making horizontal sliding, vertical sliding, and fixed windows with high energy-efficiency using only three main extrusions, along with some auxiliary hardware. The three extrusions are: (1) the main frame; (2) the sash frame; and (3) the interlock. These three extrusions may be used to form windows of any shape, including triangular, square, rectangular, or any other shape that may be formed using straight lines. 
     Using only three main extrusions overcomes the disadvantages of existing window assemblies that currently need multiple extrusions, along with auxiliary hardware. The ultimate result is to reduce retooling costs, decrease ongoing production expenses, and enable architects and engineers to more easily meet energy conservation requirements. 
     The invention described herein may be used with any materials currently used to manufacture windows. In addition, reduced tooling costs allows for implementation of the window system described herein using newer or different materials. For example, ™Xtreme Fiberglass (hereafter “Rovex”) manufactured by deceuninck is a silicon-based material that can be used to create the extrusions described herein. Rovex is described as having U-values 700 times better than aluminum in material-to-material comparisons, while retaining the strength to withstand the load requirements in commercial windows. 
     The present invention is described using the following examples, which may describe more than one relevant embodiment falling within the scope of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1A  is an elevational view of the main frame extrusion. 
         FIG. 1B  is an elevational view of the sash frame extrusion. 
         FIG. 1C  is an elevational view of the interlock extrusion. 
         FIG. 2  is an elevational view of an embodiment of the invention, showing a fixed window. 
         FIG. 3  is cross-section view along the  3 - 3  line shown in  FIG. 2 . 
         FIG. 4A  is a cross-section view along lines  4 A- 4 A as shown in  FIG. 2 . 
         FIG. 4B  is a cross-section view along lines  4 B- 4 B as shown in  FIG. 2 . 
         FIG. 5  is a plan view of an embodiment of the invention, showing a horizontal slider. 
         FIG. 6  is a cross-section view along the  6 - 6  line shown in  FIG. 5 , showing the bottom roller assembly in a horizontal slider with two panels that slide. 
         FIG. 7  is a cross-section view along the  7 - 7  line shown in  FIG. 5 , showing the head assembly of a horizontal slider with either one or two sliding panels. 
         FIG. 8  is a cross-section view along the  8 - 8  line shown in  FIG. 5 , showing the jamb assembly of a horizontal slider with either one or two sliding panels. 
         FIG. 9  is a cross-section view along the  9 - 9  line shown in  FIG. 5 , showing the interlock and lock assembly detail of a horizontal slider with either one or two sliding panels. 
         FIG. 10  is a cross-section view along the  10 - 10  line shown in  FIG. 5   
         FIG. 11  is a cross-section view along the  11 - 11  line shown in  FIG. 5 . 
         FIG. 12  is an elevational view of a single or double hung window. 
         FIG. 13  is a cross-section view along the  13 - 13  line shown in  FIG. 5 , showing the bottom panel of a single or double hung window, when the bottom panel is down and closed. 
         FIG. 14  is a cross-section view along the  14 - 14  line shown in  FIG. 5 , showing the top panel of a double hung window, when the top panel is up and closed. 
         FIG. 15  is a cross-section view along the  15 - 15  line shown in  FIG. 5 , showing the side frames of a single or double hung window, when the two panels overlap. 
         FIG. 16  is a cross-section view along the  16 - 16  line shown in  FIG. 5 , showing the interlock and lock assembly detail of a either a double hung or single hung window. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to  FIG. 1 , this shows the three main extrusions, the main frame  1 , sash frame  2 , and interlock  3 . 
     Fixed Window. 
       FIGS. 2, 3, and 4  show the use of only two extrusions, the main frame  1  and sash frame  2 , to form a fixed window. 
     The first extrusion, main frame  1 , has a width dimension, a height dimension, and a length dimension sufficient for parting off any number members as needed to forming a closed window frame. For example, three members may be parted off to form a triangular window, while four may be parted off to form a rectangular or square window. This main frame member  1  has a cross sectional profile that includes an outward presenting vertical wall extension  12 , an inward presenting vertical wall extension relative to window orientation in installation  14 , and a lateral back wall  11  bridging the vertical extensions. The lateral back wall forms a sloping surface between the vertical wall extensions. The lateral back wall  11  supports a central vertical wall extension  13 , which partition between a first and second window sash channel, where the window sash channels open to the inside of the formed frame. 
     The second extrusion is sash frame  2 , and it has a width dimension, a height dimension, and a length dimension sufficient for parting off the same number of sash frame members as main frame members, and as required to form a closed sash frame. This second extruded member has a cross sectional profile that includes a first vertical edge  21   a  and a second vertical edge  21   b.  The vertical edges define a glass channel for accepting window glass. Sash frame further comprises a first vertical leg  21   a  and second vertical leg  21   b.    
       FIG. 2  shows an elevational view of a fixed window.  FIG. 3  is a cross-sectional view of the side of a fixed window, along the line  3 - 3  as shown in  FIG. 2 .  FIG. 4A  shows a cross-sectional view of the top of a fixed window, along the  4 A- 4 A line in  FIG. 2 .  FIG. 4B  shows a cross-sectional view of the bottom of a fixed window, along the  4 B- 4 B line in  FIG. 2 . These figures show that main frame  1  is used for all outside framing. 
     Looking at  FIGS. 4A and 4B , the outside of the window is to the left, and the inside of the window is to the right. When main frame  1  is used at the bottom of a fixed window, lateral back wall  11  slopes up from left to right, that is from outside to inside. When main frame  1  is used at the top of a fixed window, lateral back wall  11  slopes down from left (outside) to right (inside), as shown in  FIG. 4A . Use of the lateral back wall  11  in main frame  1  allows water or moisture to drain out from the bottom of the window because the lowest part of the lateral back wall  11  is on the outer side of the window frame, as shown in  FIG. 4B . One or more small holes may be provided in vertical wall  12  to allow water to drain. 
     The slope on wall  11  is not typically used to drain moisture on the top or sides because moisture will not accumulate on the top or sides. But, main frame  1 , with lateral back wall  11 , is used for all sides of the window frame. 
     When main frame  1  is used for the sides of the window, as shown in  FIG. 3 , lateral back wall  11  is positioned so that extension  12  is closer to the outside, and extension  14  is closer to the inside. 
     Lateral back wall  11  is connected with vertical wall extensions  12 ,  13 , and  14 , where extension  12  is always closest to the outside. Extensions  12 ,  13 , and  14  are parallel to each other and form a first sash channel and a second sash channel. Sash frame  2  fits into either sash channel. In the fixed window embodiment, the window glass  41  fits into the glass channel defined by vertical edges  22   a  and  22   b.    FIGS. 3, 4A and 4B  show sash frame  2  with a window panel between extensions  12  and  13  on all four sides of the window. It is apparent that a fixed window panel could instead be supported between extensions  13  and  14  on all four sides of the window. 
     Glass  41  is held in the glass channel between vertical edges  22   a  and  22   b  of sash frame  2 , with the assistance of glazing gasket  46 . In a preferred embodiment, there may be two sheets of glass  41  forming a double-paned window. In other embodiments, there may be only one sheet of glass, or more than two sheets of glass. The size of the channel formed by vertical edges  22   a  and  22   b  may be varied to accommodate the different number of sheets of glass. 
     Ancillary hardware connects sash frame  2  with main frame  1 . As seen in  FIGS. 4A and 4B , wedge gasket  42  is between, and connects with, extension  12  and vertical leg  21   a  of sash frame  2 . Weather strip  43  is between, and connects with, extension  13  and weather strip receptacle  23  of sash frame  2 . Sash stop  44  is shown below vertical leg  21   b,  supporting and holding the window in position, although is it apparent that sash stop  44  may be located in any position wherein it supports and holds the window in position. Corner key  45  connects the outside surfaces of the main frame extrusions at the window corners, and is connected to the main frame extrusions with fasteners  47 . 
     Corner key  45  is used in all corners, in all window embodiments. Corner key  45  may fit between lips  16   a  and  16   b,  which retain corner key  45  in place. Lip  16   a  is somewhat shorter than lip  16   b,  to compensate for the slope of lateral back wall  11  of main frame  1 . In addition, spacers  17   a  and  17   b  may also be used to support and retain corner key  45  in place. Spacer  17   a  is somewhat shorter than spacer  17   b,  to compensate for difference between lateral back wall  11  and the flat surface of the corner key  45 . 
     Lip  19  is part of main frame  1 , and is located on the lateral back wall  11  opposite extension  14 . When main frame  1  is at the bottom of the window, lip  19  provides additional support to the window and frame, and supports the slope of main frame  1 . It is apparent that lip  19  need not be the specific shape shown in the figures. Lip  19  may be any shape that provides support for the higher, inside edge when main frame  1 . 
     In a preferred embodiment, main frame  1  may also comprise protrusions  18 . These protrusions are not absolutely necessary. However, the protrusions may provide strength to extensions  12 ,  13 , and  14 , while at the same time decreasing the amount of raw material needed to form extensions  12 ,  13 , and  14 . 
     Horizontal Slider. 
     A horizontal slider may be seen in  FIGS. 5-11 .  FIG. 5  is an elevational view of a horizontal slider. In some embodiments, horizontal slider may have one sliding panel (either on the left or the right). In other embodiments, it may have two sliding panels. In still other embodiments, a horizontal slider may have more than one fixed panel, or it may have more than two sliding panels. As non-limiting examples, a window may have two fixed panels, and one sliding panel, or it may have three sliding panels and one fixed panel. In other words, a horizontal slider may have any combination of fixed and sliding panels. 
       FIG. 6  is a cross-sectional view of the bottom of a horizontal slider with two sliding panels, with roller assemblies at the bottom of each sliding panel. Roller assemblies are known in the art, and placed below sliding panels in horizontal sliders to allow the panel to slide. A roller assembly generally comprises a roller assembly installation bracket  64 , and a roller assembly  63  connected with one or more wheels  61 . 
     Roller track spine  15  is part of the main frame  1  extrusion. A first roller track spine  15  located in the sash channel formed by extensions  12  and  13 , and a second roller track spine  15  is located in the sash channel formed by extensions  13  and  14 . Roller track spine  15  is shaped to connect with roller track  49 . In a preferred embodiment, roller track  49  is made from stainless steel and snaps onto roller track spine  15 . Roller track  49  is sized to connect with wheel  61 . In a preferred embodiment, wheel  61  has a radial groove so that wheel  61  may roll along roller track spine  15  and roller track  49 . This allows the sliding window panel to slide left to right, and right to left. 
     Vertical legs  21   a  and  21   b  form a hardware channel. The hardware channel is sized to accept the top of roller assembly installation bracket  64 . Fasteners  47  may be used to secure the roller assembly to sash frame  2 . 
     If the horizontal slider has one sliding panel, that means at least one other panel is essentially a fixed window. The top and bottom of the fixed panel would be permanently connected, as shown in  FIGS. 4A and 4B . Likewise, the side jamb of the fixed panel would permanently connected, as known in the art. 
       FIG. 7  is a cross-sectional view along line  7 - 7  in  FIG. 5 , and shows the top of a horizontal slider with one or two sliding panels, where both panels are slid to the same side. 
       FIG. 8  is a cross-sectional view along line  8 - 8  as shown in  FIG. 5 , showing the side jamb in a slider with one or two sliding panels, where both panels are slid to the same side. Handle  48  is shown on the inside panel. Handle  48  is connected with handle groove  24  of sash frame  2 . Fastener  47  may be used to secure handle  48  to sash frame  2 . 
     Sash stop  44  may be used to prevent the sliding panel from slamming into the main frame. In a preferred embodiment, sash stop  44  may rest against protrusion  18 . It is apparent that sash stop  44  may be located as desired, and does not require protrusion  18 . 
       FIG. 9  is a cross-sectional view along line  9 - 9  as shown in  FIG. 5 , showing a horizontal slider with one or two sliding panels, with both panels closed. Each panel has interlock  3 . 
     Interlock  3  is a third extruded member with a width dimension, a height dimension, and a length dimension sized to fit within the window frame assembly. The interlock has a cross sectional profile that includes a back strip  31 , and two opposing and substantially parallel snap ridges  32  that form snap channel furrow, and an interlock lip wall  33 . The snap channel furrow is strategically formed and spaced to facilitate snap in installation, so that snap ridges  32  snap into the hardware channel of the sash frame. 
     The figures show a preferred embodiment, where the snap ridges have different shapes to facilitate the snap-in action, and allow them to snap into bulbs  25 . It is apparent that the snap ridges do not need to be different shapes, and may be any shape that allows for connection between interlock  3  and sash frame  2 . In some embodiments, glue may be used to further secure connectors  32  with legs  21 . 
     The interlock lip  33  positioned over and opposed to an interlock lip  33  on an identical inverted interlock extrusion  3  that is connected with the hardware channel of a second sash frame extrusion. Interlock lips  33  are offset with clearance for the interlock lips to overlap in operation. 
     Lip  33  on a first window panel interlocks with lip  33  on a second window panel when both panels are closed. This secures the two panels together. Weather strip  43  may be located between lip  33  of a first panel, and weather strip receptacle  23  on a second panel. This prevents air from simply flowing between the two window panels. 
     Handle  48  is on the inside of the window. To open the window, a user may grasp handle  48 , and slide the panel in the direction of the “x” arrow. The lips  33  will separate and the panel will slide in the direction of the “x” arrow. The action is the same whether the window has one or two sliding panels. If only one panel slides, then the other panel remains fixed. If both panels slide, then, in a preferred embodiment, the second panel, that is closer to the outside, will also have a handle  48  connected with sash frame  2  on the inside surface of this second panel. 
       FIG. 9  also shows some ancillary hardware used in sliders, including lock  51  secured to interlock  3  with fastener  47 . On the inside window panel, fastener  47  securely connects lock  51  with interlock  3 . On the inside window panel, handle  48  is connected to handle groove  24  on interlock  3 . In a preferred embodiment fastener  47  connects handle  48  to interlock  3 . 
       FIGS. 10  shows the bottom main frame of a single panel of a sliding glass window. Also shown is sash filler  65 . This piece is ancillary hardware, that may be used to complete the window frame, and may provide additional security and stability to a window frame. Likewise,  FIG. 11  shows a top frame of a single panel of a sliding glass window with sash filler  65 . 
     Vertical Hung Windows. 
       FIGS. 12 to 16  shows use of the invention in vertical hung windows. Vertical hung windows are similar in many respects to horizontal sliders. Vertical double-hung windows are similar to horizontal sliders with two panels that move, and vertical single-hung windows are similar to horizontal sliders with one panel that moves and one panel that does not. 
       FIG. 12  is an elevational view of a single or double hung window.  FIG. 13  shows the bottom window jamb in either a single or double hung window, with the inside bottom window panel all the way down and closed. Main frame  1  forms the bottom frame, as described herein. In the closed position, sash frame  2  rests on sash stop  44 , and sash stop  44  provides some support to the window panel. In a preferred embodiment, protrusion  18  holds sash stop  44  in position. In other embodiments, protrusion  18  is not necessary, and sash stop  44  may be held in place with glue or other materials. Leg  22   b  faces inside, and handle  48  is connected with groove  24 , where groove  24  is on the inside underneath leg  22   b.  Handle  48  may be secured in place by fastener  47 . The window may be raised by grasping handle  48  and lifting the window panel up and out of main frame  1 . Sash frame  2 , along with weather strip  43  will be lifted and the window will open. 
       FIG. 14  shows the top window frame in a double hung window, with the top, outer window panel all the way up and closed. Main frame  1  forms the top frame, as described herein. In the closed position, sash frame  2  may connect with sash stop  44 . It is apparent that sash stop  44  is not providing support for this top window panel, but sash stop  44  may prevent the top window panel from smashing into the top main frame when being raised. Leg  22   b  of sash frame  2  faces inside, and handle  48  is connected with groove  24 , where groove  24  is on the same side as leg  22   b.  Handle  48  may be secured in place by fastener  47 . The window may be lowered by grasping handle  48  and pulling the window panel down and out of main frame  1 . Sash frame  2 , along with weather strip  43  will be lowered and the window will open. 
       FIG. 15  shows the side window frame of a double hung window, where extension  14  faces inside, and extension  12  faces outside. Main frame  1  and sash frame  2  are connected, and support glass  41  as described herein. Ancillary hardware includes balance  67 , which is used to facilitate raising and lowering the window panels.  FIG. 15  depicts a double hung window, wherein each window panel that moves may have a balance. In a single hung window, only the moving panel will have a balance. 
     The cross-sectional views in  FIGS. 13 and 14 and 15  also show corner key  45 , located in the window corners and used to fasten together the corners of the window. 
       FIG. 16  shows the interlock mechanism for a single or double hung window, and functions as described herein for horizontal sliders. Each panel has interlock  3 . Interlock  3  connects the two panels, and is comprised of base  31 , with two small connectors  32 , and a lip  33 . 
     Lip  33  on a first window panel interlocks with lip  33  on a second window panel when both panels are closed. This secures the two panels together. Weather strips  43  may be located between lip  33  of a first panel, and weather strip receptacle  23  on a second panel. This prevents air from simply flowing between the two window panels. 
     In  FIG. 16 , the widow may be opened by grasping handle  48  and raising the window up, so that lip  33  on the inside window panel lifts up and away from lip  33  on the second, outside window panel. 
     Use of Different Materials. 
     There are now materials with a modulus of elasticity between 7,900,000 lbs/inch squared and 10,000,000 lbs/inch squared while achieving U-values at or below the standards set by the regulating agencies. For example, deceuninck North America, a PVC extrusion company, describes its Rovex™ as having U-values 700 times better than aluminum in material-to-material comparisons, while retaining the strength to withstand the load requirements in commercial windows. By using an extrusion that is 80% glass, the COTEs and U-values of all of the components of the window system are basically comparable. Accordingly, the U-value of the entire window system would be determined primarily by the glass configuration. For example, if the U-value of the new material is 0.17, and that of the insulated glass unit were 0.24, the whole system U-value would be 0.24, which would meet all of the existing energy requirements in place now, and those proposed in the future. 
     The invention described herein requires only three main extrusions to assemble vertical sliding windows (single hung and double hung), horizontal sliding windows, and only two main extrusions to assemble fixed windows, where the windows may have any number of outside edges. This means that the tooling costs will be much reduced to make this new window system, while simultaneously achieving existing and anticipated energy-efficiency requirements, and providing the strength needed for all window types. 
     The above description presents the best mode contemplated in carrying out the invention(s) described herein. However, it is susceptible to modifications and alternate constructions from the embodiments shown in the figures and accompanying description. Consequently it is not intended that the invention be limited to the particular embodiments disclosed. On the contrary, the invention is intended to cover all modifications, sizes and alternate constructions falling within the spirit and scope of embodiments of the invention.