Patent Publication Number: US-8112941-B2

Title: Construction product having a moveable element with multi-functional thermal break

Description:
BACKGROUND 
     This application discloses an invention that is related, generally and in various embodiments, to a construction product having a multi-functional thermal break. 
     Windows, doors, and other construction products that serve as a barrier between the interior and exterior of a structure are most desirable when they have functional, aesthetically pleasing, and thermal insulating properties. However, prior art construction products are lacking in many of these features. In particular, products with moveable parts, such as windows and doors, may include a thermal barrier element in order to substantially block the passage of thermal energy between two elements. However, prior art thermal barriers exhibit several disadvantages. For example, they may not provide a substantial seal against external temperatures, they may not provide structural support for other elements of the construction product, or they may be structurally complicated and thus expensive and difficult to manufacture. 
     The embodiments described herein are directed to solving one or more of the problems described above. 
     SUMMARY 
     In an embodiment, a construction product such as a window or door includes a frame and a sash. The sash includes an interior portion, an exterior portion, and a thermal break. The thermal break is made of a rigid insulating material that connects and supports the interior portion and the exterior portion. The construction product also includes a support member that is operatively connected to the sash and which supports the sash when the sash is in multiple positions. The thermal break defines a cavity that accepts the support member. The frame may be made of a material such as aluminum, while the thermal break may be made of a different material such as a polymer. 
     Optionally, the interior portion includes a first rail portion, the exterior portion includes a second rail portion, and the support member is a pivot bar. In such an embodiment, the cavity may surround the pivot bar. The sash also may include a glazing component. The construction product also may, in some embodiments, include a second thermal break that further connects and supports the interior portion and the exterior portion. 
     In some embodiments, the frame may include a first sill portion, a second sill portion, and an additional thermal break that connects and supports the first and second sill portions. 
     In another embodiment, a construction product includes a frame and a first sash. The first sash includes an interior first sash portion, an exterior first sash portion, and a first thermal break. The first thermal break comprising may be made of an insulating material that connects and supports the interior first sash portion and the exterior first sash portion. A first support member may be operatively connected to the first sash so that it supports the first sash when the first sash is multiple positions. The first thermal break may define a cavity that accepts the first support member. The construction product also may include a second sash that includes an interior second sash portion, an exterior second sash portion, and a second thermal break. The second thermal break may be made of an insulating material that connects and supports the interior second sash portion and the exterior second sash portion. A second support member may be operatively connected to the second sash so that it supports the second sash when the second sash is in multiple positions, the second thermal break may define a cavity that accepts the second support member. The frame may be made of a material such as aluminum, while the thermal break may be made of a different material such as a polymer 
     Optionally, the frame may include a first sill portion, a second sill portion and an additional thermal break that connects and supports the first and second sill portions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various embodiments of the invention are described herein by way of example in conjunction with the following figures. 
         FIG. 1  illustrates various embodiments of a construction product, in this example a window with a sash. 
         FIG. 2  illustrates a cross-section of the construction product of  FIG. 1  according to various embodiments. 
         FIG. 3  illustrates another cross-section of a construction product such as that shown in  FIG. 1  according to various embodiments. 
         FIG. 4  illustrates another cross-section of a construction product such as that shown in  FIG. 1  according to various embodiments. 
         FIG. 5  illustrates a variation of the cross section of  FIG. 4 . 
         FIG. 6  illustrates an alternate embodiment of a construction product, in this example a sliding window or door. 
         FIG. 7  illustrates a cross section of a portion of the construction product of  FIG. 6 . 
         FIG. 8  illustrates a variation of the embodiment of  FIG. 7  including two sashes. 
         FIG. 9  illustrates a double-sliding window or door. 
         FIG. 10  illustrates a construction product such as that shown in  FIG. 6  with a moveable sash. 
     
    
    
     DETAILED DESCRIPTION 
     Before the present methods, systems and materials are described, it is to be understood that this disclosure is not limited to the particular methodologies, systems and materials described, as these may vary. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope. For example, as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. In addition, the word “comprising” as used herein is intended to mean “including but not limited to.” Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art, 
       FIG. 1  illustrates various embodiments of a construction product  10 . The construction product  10  may be embodied as, for example, a single hung window or a double hung window. The construction product  10  includes a frame  12 , and a sash  14  surrounded by the frame  12 . 
     The frame  12  includes a sill  16 , a head  18 , a first jamb  20  connected to the sill  16  and the head  18 , and a second jamb  22  connected to the sill  16  and the head  18 . The sill  16 , the head  18 , and the first and second jambs  20 ,  22  may each be fabricated from any suitable material. According to various embodiments, at least a portion of the sill  16 , the head  18 , the first jamb  20  and/or the second jamb  22  is fabricated from a metal. The metal may include for example, aluminum. 
     For purposes of clarity, only one sash  14  is shown in  FIG. 1 . However, those skilled in the art will appreciate that the construction product  10  may include any number of sashes  14 . For embodiments having two sashes  14 , one of the sashes  14  may be considered the “top” sash and the other of the sashes  14  may be considered the “lower” sash as understood by those skilled in the art. A given sash  14  may be embodied as either a fixed sash or a moveable sash, and the construction product  10  may include any combination of fixed and/or moveable sashes  14 . 
     The sash  14  includes a glazing component  24 . The glazing component  24  is an element through which light may pass, and it may be of any suitable material. For example, according to various embodiments, the glazing component  24  may be an insulated glass. As shown in  FIG. 1 , the sash  14  may also include a rail  26 , a checkrail  28 , a first stile  30  connected to the rail  26  and the checkrail  28 , and a second stile  32  connected to the rail  26  and the checkrail  28 . The rail  26 , the checkrail  28 , and the first and second stiles  30 ,  32  may each be fabricated from any suitable material. According to various embodiments, at least a portion of the rail  26 , the checkrail  28 , the first stile  30  and/or the second stile  32  is fabricated from a metal. The metal may include, for example, aluminum. 
       FIG. 2  illustrates a cross-section of a portion of the construction product of  FIG. 1 , according to various embodiments, and shows the sill  16  portion of the frame and the rail  26  portion of the sash. The sill  16  receives the sash  26  when the sash is in a closed position. The sill  16  includes a first sill portion  34 , a second sill portion  36 , and a thermal break  38  connected to the first and second sill portions  34 ,  36 . The first sill portion  34  may be considered an “exterior” portion of the frame, and the second sill portion  36  may be considered an “interior” portion of the frame. The thermal break  38  may be fabricated from any suitable material. According to various embodiments, the thermal break  38  is fabricated from a polymer. The polymer may include, for example, a polyamide. The thermal break  38  operates to limit thermal conduction between the first and second sill portions  34 ,  36 . The sill  16  may include any number of thermal breaks  38 . For example, according to various embodiments, the sill  16  may include two thermal breaks  38  connected to the first and second sill portions  34 ,  36  as shown in  FIG. 2 . 
     The rail  26  includes a first rail portion  40 , a second rail portion  42 , and a two-piece thermal break  44 A/B (collectively referred to herein as element  44 ) connected to the first and second rail portions  40 ,  42 . As shown in  FIG. 2 , the glazing component  24  is between the first and second rail portions  40 ,  42 . The first rail portion  40  may be considered an “exterior” portion of the sash, and the second rail portion  42  may be considered an “interior” portion of the sash. The thermal break (shown made of two portions  44 A and  44 B, collectively referred to herein as  44 ) may be fabricated from any suitable material. According to various embodiments, the thermal break  44  is fabricated from a polymer. The polymer may include, for example, a polyamide. The thermal break  44  operates to limit thermal conduction between the first and second rail portions  40 ,  42 . The rail  26  may include any number of thermal break portions  44 . For example, according to various embodiments, the rail  26  may include a two-part thermal break  44 A/ 44 B connected to the first and second rail portions  40 ,  42  as shown in  FIG. 2 . For such embodiments, one of the thermal break portions  44 A may define a cavity that accepts and surrounds a pivot bar  46  of the construction product, and the other of the thermal break portions  44 B may define at least a portion of a cavity that accepts a screw, i.e., a screw boss  48 . The pivot bar  46  may be utilized to pivot and support the sash  14  in multiple positions as is known in the art. The screw boss  48  may be used to receive a screw which serves to connect the first or second stile ( 30 ,  32  in  FIG. 1 ) with the rail  26 . From the foregoing, one skilled in the art will appreciate that the thermal break  48  is a multi-functional thermal break. 
       FIG. 3  illustrates a cross-section of a portion of a construction product such as that shown in  FIG. 1 , and shows the head  18  of the frame and a glazing component  24 . As shown in  FIG. 3 , a thermal break  61  is made up of elements  61 A and  61 B (collectively referred to herein as element  61 ). A thermal break portion  61 B may be configured to define at least a portion of a cavity  69  that receives a glazing bead  70  of the construction product and holds the glazing bead  70  in place. As shown in  FIG. 3 , the cavity  69  may be defined on at least three sides and optionally on a portion of the fourth side, by the thermal break portion  61 B. A weather strip  71  may be connected to the glazing bead so that it also contacts the glazing component  24  and provides a weather-resistant seal. The glazing bead  70  may support the glazing component  24  during construction, and thereafter the glazing bead  70  may serve an aesthetic function and shield the edge of glazing component  24  from view. The glazing bead  70 , when connected to the thermal break portion  61 B, cooperates with the first head potion  56  to fix the position of the “upper” sash, and in particular the glazing component  24 . Alternatively, elements  56  and  58  may make up a portion of a sash  18  and thermal break  61 B may cooperate with sash portions  56  and  58 . Accordingly, the thermal break  61  is a multi-functional in that it provides both insulating and structural functions. 
       FIG. 4  illustrates a cross-section of a portion of a construction product such as that shown in  FIG. 1 . In this embodiment, a window is shown with the first jamb  20  of the frame, a first stile  30  of each of a first moveable sash. The stile  30  receives and supports a glazing component  24 . The embodiment shown in  FIG. 4  may include two or more moveable sashes, and thus is shown with a second stile  31  relating to a second moveable sash  25 . The first jamb  20  includes a first jamb portion  72 , a second jamb portion  74 , and a thermal break  76 A connected to the first and second jamb portions  72 ,  74 . The First jamb portion  72  may be considered an “exterior” portion of the frame, and the second jamb portion  74  may be considered an “interior” portion of the frame. The thermal break  76 A may be fabricated from any suitable material to provide a rigid or semi-rigid structural support. According to various embodiments, the thermal break  76 A is fabricated from a polymer. The polymer may include, for example, a polyamide. The thermal break  76 A operates to limit thermal conduction between the first and second jamb portions  72 ,  74 . The first jamb  20  may include any number of thermal breaks. For example, according to various embodiments, the first jamb  20  may include two thermal breaks  76 A and  76 B connected to the first and second jamb portions  72 ,  74  as shown in  FIG. 4 . One of the thermal breaks  76 A cooperates with one of the Jamb portions  74  to define a first cavity  78  that houses a moveable component  80  of the construction product. The thermal break  76 A is structured to provide a U-shaped wall that defines at least a portion each of three sides of cavity  78 , while the jamb portion  74  also provides at least a portion of three sides of the cavity  78 . As shown in  FIG. 4 , cavity  78  need not be entirety enclosed. The moveable component  80  may be, for example, a counterbalance mechanism connected to the sash  24  or a tilt shoe connected to the pivot bar of the construction product. The moveable component  80  supports the sash in multiple positions, including various open positions. Accordingly, thermal break  76 A is a multi-functional thermal break in that it provides both insulating and structural support functions. 
     The first stile  30  includes a first stile portion  82 , a second stile portion  84 , and a thermal break  86  connected to the first and second stile portions  82 ,  84 . As shown in  FIG. 4 , the glazing component  24  is between the first and second stile portions  82 ,  84 . The first stile portion  82  may be considered an “exterior” portion of the sash  14 , and the second stile portion  84  may be considered an “interior” portion of the sash  14 . The thermal break  86  may be fabricated from any suitable material. According to various embodiments, the thermal break  86  is fabricated from a polymer. The polymer may include, for example, a polyamide. The thermal break  86  operates to limit thermal conduction between the first and second stile portions  82 ,  84 . The first stile  30  may include any number of thermal breaks  86 . For example, according to various embodiments, the first stile  30  may include two thermal breaks  86  connected to the first and second stile portions  82 ,  84  as shown in  FIG. 4 . 
     Optionally, where a second moveable sash  25  is provided the thermal break  76 A may define not only a portion of first cavity  78 , but also a portion of second cavity  79 . Thermal break  76 A provides a U-shaped wall that defines at least a portion of three sides of second cavity  79 . Second cavity  79  holds a second moveable component  81 . Second moveable component  81  may be, for example, a counterbalance mechanism connected to sash  25  or a tilt shoe connected to a pivot bar of the construction product. Where a second sash  25  is used, a corresponding first stile portion  83  and second stile portion  85  may be used to accept the second sash  25 . Either or both of the second (interior) stile portions  82 ,  83  may include a weather strip  35 ,  36  that extends from its corresponding stile portion and contacts the thermal break to form a weather-resistant seal. 
       FIG. 5  is a variation of the embodiment of  FIG. 4  and it illustrates a cross-section of construction product with an “interior” moveable sash  14  and the first jamb  20  of the frame below the checkrail of the “interior” moveable sash  14 . Although otherwise similar to a portion of  FIG. 4  with a single sash  24 , in  FIG. 5  the sash  82  includes a flexible portion  88  which is in contact with an extended member  73  of the thermal break  77 A. The flexible portion  88  may operate as a weather strip so that when weather strip  88  contacts the thermal break  77 A a water-resistant seal is provided. 
       FIG. 6  illustrates an alternate embodiment of a construction product  110 , in this example a sliding window or door The construction product  110  includes a frame  1127  and a sash  114  surrounded by the frame  112 . 
     The frame  112  includes a sill  116 , a head  118 , a first jamb  120  connected to the sill  116  and the head  118 , and a second jamb  122  connected to the sill  116  and the head  118 . The sill  116 , the head  118 , and the first and second jambs  120 ,  122  may each be fabricated from any suitable material. According to various embodiments, at least a portion of the sill  116 , the head  118 , the first jamb  120  and or the second jamb  122  may be fabricated from a metal. The metal may include, for example, aluminum. 
     For purposes of clarity, only one sash  114  is shown in  FIG. 6 . However, those skilled in the art will appreciate that the construction product  110  may include any number of sashes  114 . A given sash  114  may be embodied as either a fixed sash or a moveable sash, and the construction product  110  lay include any combination of fixed and/or moveable sashes  114 . For embodiments having two or more sashes  114 , at least one sash  114  may be considered the “exterior” sash and at least one sash  114  may be considered the “interior” sash. 
     The sash  114  includes a glazing component  124 . The glazing component  124  may be of any suitable material. For example, according to various embodiments, the glazing component  124  may be an insulated glass. As shown in  FIG. 6 , the sash  114  may also include a first rail  126 , a second rail  128 , a first stile  130  connected to the first and second rails  126 ,  128 , and a second stile  132  connected to the first and second rails  126 ,  128 . The first rail  126  may be considered the “lower” rail and the second rail  128  may be considered the “upper” rail. The first and second rails  126 ,  128  and the first and second stiles  130 ,  132  may each be fabricated from any suitable material. According to various embodiments, at least a portion of the first rail  126 , the second rail  128 , the first stile  130  and/or the second stile  132  may be fabricated from a metal. The metal may include, for example, aluminum. 
       FIG. 7  illustrates a cross-section of a construction product such as that shown in  FIG. 6 , and it shows a portion of a sill  116  of a frame. The sill  116  receives the first rail of a moveable sash  114 . The sill  116  includes a first sill portion  134 , a second sill portion  136 , and a thermal break  138  (in this example made of two portions  138 A and  138 B) connected to the first and second sill portions  134 ,  136 . The first sill portion  134  may be considered an “exterior” portion of the frame, and the second sill portion  136  may be considered an “interior” portion of the sill  116 . The thermal break  138  may be fabricated from any suitable rigid or semi-rigid material. According to various embodiments, the thermal break  138  is fabricated from a polymer that has both thermal insulation and structural support properties. The polymer may include, for example, a polyamide. The thermal break  138  operates to limit thermal conduction between the first and second sill portions  134 ,  136 . The sill  116  may include any number of thermal breaks  138 . For example, according to various embodiments, the sill  116  may include two thermal break portions  138 A and  138 B connected to the first and second sill portions  134 ,  136  as shown in  FIG. 7 . 
     As shown in  FIG. 7 , the sill  116  may also include a rigid member  140  connected to the first sill portion  134  and the thermal break  138 . The rigid member  140  may be fabricated from any suitable material. According to various embodiments, the rigid member  140  may be fabricated from a plastic, the plastic may include, for example, a polyvinyl chloride. The rigid member  140  may cooperate with the first sill portion  134  and the thermal break  138  to increase the strength and/or stiffness of the sill  116 . The thermal break  138  defines at least a portion, and in  FIG. 7  three sides of a cavity  139  that accepts the rigid member  140  of the sill  116 . Accordingly, the thermal break  138  is a multi-functional thermal break in that it serves both insulating and structural functions. Optionally, a second thermal break  137  may cooperate with first sill portion  134  and second sill portion  136  to further increase the strength of the sill  116 . 
     The first rail of moveable sash  114  includes a first rail portion  142 , a second rail portion  144 , and a thermal break  146  (in this example made of two portions  146 A and  146 B) connected to the first and second rail portions  142 ,  144 . As shown in  FIG. 7 , the glazing component  124  is between the first and second rail portions  142 ,  144 . The first rail portion  142  may be considered an “exterior” portion of the sash  114 , and the second rail portion  144  may be considered an “interior” portion of the sash  114 . The thermal break  146  may be fabricated from any suitable rigid material. According to various embodiments, the thermal break  146  is fabricated from a polymer. The polymer may include, for example, a polyamide. The thermal break  146  operates to limit thermal conduction between the first and second rail portions  142 ,  144 . The first rail  126  may include any number of thermal breaks or thermal break portions  146 A and  146 B. For example, according to various embodiments, the first rail  126  may include two thermal break portions  146 A and  146 B connected to the first and second rail portions  142 ,  144  as shown in  FIG. 7 . A thermal break or thermal break portion  146 B may surround or receive a roller mechanism  148  of the construction product. The cavity  147  may be an opening to receive the roller  148  into the thermal break as shown in  FIG. 8 . Alternatively, the cavity  147  may be an indentation or groove that simply receives and guides the roller along the thermal break portion  146 $. The roller mechanism  148  may be use to slide the sash  114  as is known in the art. From the foregoing, the thermal break  146  is a multi-functional thermal break. 
       FIG. 8  shows a variation on the embodiment of  FIG. 7  in which thermal break  150  provides thermal insulation and support between a first sill portion  134  and second sill portion  136 . This embodiment includes two sashes  114 , each including a glazing component  124 , and a two-part thermal break  146  that includes a portion  146 B with a cavity  147  that receives a roller mechanism  148 . Thus, the embodiment shown in  FIG. 8  may be, for example, a double sliding door mechanism. Optionally, one or more interior rail portions  142 ,  145  may include a weather strip  151 ,  152  that extends from its corresponding rail portion and creates a water-resistant seal by contacting the thermal break  139 . Alternatively, the weather strip portions  151  and  152  may be integral with thermal break  150  and may extend into rail portions  142  and  145 . 
       FIG. 9  shows an embodiment of a double-sliding window or door with a head including a first head portion  171  and a second head portion  172  and a thermal break  173  that connects and supports the first and second head portions. Thermal break  173  includes a first member  175  and a second member  176 . The first member  175  connects and supports the first head portion  171  and second head portion  172 . The second member  176  is connected to the first member  175 , extends in a substantially perpendicular direction from first member  175 . Second member  176  either receives one or more weather strips  177 ,  178  from one or both rail portions  181 ,  182 , or second member  176  includes one or more weather strips  177 ,  178  that extend and contact one or both rail portions  181 ,  182 . 
       FIG. 10  illustrates a cross-section of a construction product such as that shown in  FIG. 7  according to various embodiments, and shows the head  1  IS of the frame. The head  118  receives the second rail of a moveable sash  114 . The head  118  includes a first head portion  154 , a second head portion  156  and a thermal break  158  connected to the first and second head portions  154 ,  156 . The first head portion  154  may be considered an “exterior” portion of the frame, and the second head portion  156  may be considered an “interior” portion of the frame. The thermal break  158  may be fabricated from any suitable material. According to various embodiments, the thermal break  158  is fabricated from a polymer. The polymer may include, for example, a polyamide. The thermal break  158  operates to limit thermal conduction between the first and second head portions  154 ,  156 . The head  118  may include any number of thermal breaks  158 . For example, according to various embodiments, the head  118  may include two thermal break portions connected to the first and second head portions  154 ,  156  as shown in  FIG. 10 . 
     As shown in  FIG. 10 , the head  118  may also include a rigid member  160  connected to the first head portion  154  and the thermal break  158 . The rigid member  160  may be fabricated from any suitable material. According to various embodiments, the rigid member  160  may be fabricated from a plastic. The plastic may include, for example, a polyvinyl chloride. The rigid member  160  may extend into a cavity  161  of the thermal break  158  cooperate with the first head portion  154  and the thermal break  158  to increase the strength and/or stiffness of the head  118 . Thus, the thermal break  158  is a multi-functional thermal break in that it provides thermal insulation and supports the structure of the head. 
     The second rail  128  includes a first rail portion  162 , a second rail portion  164 , and a thermal break  166  (made of portions  166 A and  166 B) connected to the first and second rail portions  162 ,  164 . As shown in  FIG. 10 , the glazing component  124  is positioned between and supported by the first and second rail portions  162 ,  164 . The first rail portion  162  may be considered an “exterior” portion of the sash  114 , and the second rail portion  164  may be considered an “interior” portion of the sash  114 . The thermal break  166  may be fabricated from any suitable material. According to various embodiments, the thermal break  166  is fabricated from a polymer. The polymer may include, for example, a polyamide. The thermal break  166  operates to limit thermal conduction between the first and second rail portions  162 ,  164 , and it also supports the first and second rail portions  162 ,  164 . The second rail  128  may include any number of thermal breaks  166 . For example, according to various embodiments, the second rail  128  may include two or more thermal break portions  166 A and  166 $ connected to the first and second rail portions  162 ,  164  as shown in  FIG. 10 . 
     While several embodiments of the invention have been described herein by way of example, those skilled in the art will appreciate that various modifications, alterations, and adaptions to the described embodiments may be realized without departing from the spirit and scope of the invention defined by the appended claims.