Patent Publication Number: US-2015069782-A1

Title: Modular Window System for Passenger Vehicle

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims priority from U.S. Provisional Application 61/876,028, filed Sep. 10, 2013, and entitled “Modular Window System for Passenger Vehicle,” which is hereby incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The disclosed apparatus, methods and system relate to an improved and methods novel passenger vehicle including a window assembly. 
     BACKGROUND OF THE INVENTION 
     The presently disclosed embodiments relate to various apparatus, systems and methods relating to a modular window design for passenger vehicles. 
     Prior art designs for windows frequently feature clamp ring and flange designs, which are inefficient and frequently leak, causing undesirable water flow into the body of the vehicle. As a result, typical passenger vehicle designs feature a “drip rail,” or other awning-style means to attempt to prevent liquid from entering the cabin of the vehicle. Further, typical passenger vehicles are frequently assembled by forming the body and then cutting window holes to place the windows in. 
     Prior designs also frequently are assembled with seams that run vertically over the top of the roof to accommodate the front and rear transition portions, which also create a host of leakage and other problems. The presently disclosed apparatus, systems and methods disclose a novel passenger vehicle system which addresses these flaws in the prior art. 
     BRIEF SUMMARY OF THE INVENTION 
     As discussed herein, the “window assembly” relates to various apparatus, systems and methods relating to a novel roof and window assembly of a passenger vehicle, such as a bus. While various embodiments will be referred to herein as “the window assembly” or “the roof assembly” for brevity, these apparatus, systems and methods are all contemplated. The window assembly acts to prevent water leaks through the windows of the vehicle, and to allow for the installation of windows into the frame later in construction. 
     The disclosure relates to apparatus, systems and methods for assembling a passenger vehicle including an improved system for modular window assemblies on passenger vehicles, such as busses. These passenger vehicles feature a unified roof component and modular window units which are configured to be installed directly onto the frame such that the roof and sidewall are correspondingly joined by way of joints. In further implementations, a forward transition region is installed which is also fixedly attached to the unified roof component by way of an H section joint. 
     While multiple embodiments are disclosed, still other embodiments of the window assembly will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a passenger vehicle comprising the window assembly, according to an exemplary embodiment. 
         FIG. 2  is a further perspective side view of the embodiment of  FIG. 1 . 
         FIG. 3  is a reverse side vide of the embodiment of  FIGS. 1-2 . 
         FIG. 4A  is a front view of a passenger vehicle with the window assembly, according to an exemplary embodiment. 
         FIG. 4B  is the back view of the embodiment of  FIG. 4A . 
         FIG. 5  is a perspective view of the frame of the window assembly, according to one embodiment. 
         FIG. 6A  is a perspective view of an exemplary embodiment of the window assembly wherein the frame is mounted on a chassis in assembly. 
         FIG. 6B  is another perspective view of the embodiment of  FIG. 6A , further showing an embodiment of the forward transition. 
         FIG. 7A  is a perspective view of the frame assembled and attached to the chassis, according to an exemplary embodiment. 
         FIG. 7B  is a interior view of the frame with the unified roof component mounted in place, according to an exemplary embodiment. 
         FIG. 7C  is a side view of the modular window openings fit around the frame&#39;s cage tubes, according to one embodiment. 
         FIG. 7D  depicts an exemplary embodiment comprising a retainer, or “inner cap” to lock the modular windows in place. 
         FIG. 8  depicts yet another perspective view of the forward transition installed on the chassis, according to one embodiment. 
         FIG. 9A  is a rear perspective view of one embodiment of the unified roof component. 
         FIG. 9B  is a rear perspective view of the embodiment of  FIG. 9A , wherein the unified roof component has been placed on the frame. 
         FIG. 10  is a cross section of one embodiment of the window assembly showing the unified roof component transition joint with the forward transition, comprising the H section. 
         FIG. 11  is a further cross-sectional view of the assembly showing the wedge shaped member, according to an exemplary embodiment. 
         FIG. 12A  is an endlong perspective view of one embodiment of the wedge shaped member. 
         FIG. 12B  is a further endlong perspective view of the wedge shaped member, according to the embodiment of  FIG. 12A . 
         FIG. 13  is a side view of the transition joint, according to an exemplary embodiment. 
         FIG. 14  is a further perspective view of the window assembly, according to an exemplary embodiment. 
         FIG. 15  is an internal view of the embodiment of  FIG. 14 . 
         FIG. 16  is a cross-sectional view of the window assembly, showing the window joints, windows, and mulling, according to an exemplary embodiment. 
         FIG. 17  is a detailed view of the top window joint portion of the embodiment of  FIG. 16 . 
         FIG. 18  is a detailed view of the central, mulling portion of  FIG. 16 . 
         FIG. 19  is a detailed view of the bottom window joint portion of the embodiment of  FIG. 16 . 
         FIG. 20  is a transverse view of the embodiment of  FIG. 16 . 
         FIG. 21  detailed perspective view of the transition from the H section of the forward transition region to the window assembly region joint, according to an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Prior art designs for windows frequently feature clamp ring and flange designs, which are inefficient and frequently leak, causing undesirable water flow into the body of the vehicle. As a result, typical passenger vehicle designs feature a “drip rail,” or other awning-style means to attempt to prevent liquid from entering the cabin of the vehicle. Further, typical passenger vehicles are frequently assembled by forming the body and then cutting window holes to place the windows in. Prior designs also frequently are assembled with seams that run vertically over the top of the roof to accommodate the front and rear transition portions, which also create a host of leakage and other problems. The present apparatus, systems and methods disclose a novel passenger vehicle window and roof assembly which addresses these flaws in the prior art. 
     The window assembly unit seeks to address these issues in the prior art by providing a modular window assembly and unified roof for a passenger vehicle. In exemplary implementations, the vehicle features a chassis, a frame mounted on the chassis, a generally rectangular unified roof component further comprising front and back ends and side portions a top window joint, a bottom window joint, a sidewall and at least one modular window unit further comprising a top and bottom, such that the at least one modular window unit is disposed between the sides of the unified roof component and sidewalls by way of the top window joint and bottom window joint. Certain exemplary implementations further comprise an H section joint and forward transition region, wherein the transition is fixedly attached to the chassis, wherein the H section joint is disposed between the unified roof component and the transition region. 
     Referring now to the figures with particularity,  FIGS. 1-4  depict various views of vehicles  1  comprising exemplary embodiments of the window assembly  10 . These embodiments generally comprise a novel unified roof component  12 , at least one modular window unit  14 , and window joints, or transition regions  22 ,  24 . In these embodiments, the present apparatus systems and methods allow for a window assembly in which window units can be completely assembled separate from the vehicle and installed when vehicle manufacture has neared or reached completion.  FIGS. 5-16  depict various views of the assembly of the vehicle according to the present disclosure according to exemplary embodiments. As would be apparent to one of skill in the art, the present system can be scaled to be utilized on vehicles of various other sizes and configurations. 
     Turning to the figures in detail,  FIGS. 1-4B  depict external views of a passenger vehicle  1  utilizing an exemplary embodiment of the present system  10 . In these embodiments, the window assembly  10  further comprises a generally rectangular unified roof component  12 , modular window units  14 , an “H section” joint  16 , a forward transition region  18 , a sidewall  20 , and window transition regions  22 ,  24 . While fiberglass is typically used for the forward transition region and sidewall in these embodiments, other building materials may be utilized. 
     As depicted in  FIG. 2 , in certain embodiments, the unified roof component  12  further comprises generally square front  12 A and back  12 B ends side portions  12 C, a top  12 D and bottom  12 E, and generally rounded corners  12 F. In certain embodiments, the window joints  22 ,  24  are attached between a side portion  12 C and the modular window units  14 . 
     As depicted in  FIGS. 1-4B , in addition to the unified roof component  12 , exemplary embodiments the window assembly also comprise an “H-Section” joint  16 , forward transition  18  and a rear portion  30 . In certain embodiments, the rear portion is fiberglass as well. In certain exemplary embodiments, the forward transition region  18  is configured to be fixedly attached to the underside, or bottom  12 E portion of the unified roof component, by way of the H section joint  16 . In these embodiments the H-Section  16  allows the vehicle  1  to be assembled such that the unified roof component  12  seam (at  16 ) is substantially horizontal to the ground, which is a substantial improvement over the prior art models, which feature vertical seams. The embodiments featuring an H-Section present significant additional improvements over the prior art, and are described herein below. 
     Further, in certain embodiments the window assembly  10  can further comprise openings for entrance doors  26  and lift access doors  28  on at least one side of the vehicle  1 , as is best shown in  FIG. 2 . Various vehicle embodiments can also comprise other means of ingress and egress, as would be apparent to one of skill in the art. 
     As depicted in  FIGS. 5-7 , exemplary embodiments of the window assembly  10  comprise a frame  32 , which the completed assembly is fixedly attached to. In certain embodiments, and as shown generally in  FIG. 5 , the frame  32  features a roll cage structure  34  and at least one modular window frame  36  having at least one modular window opening  38 . The modular window opening  38  can further comprise novel extrusions  40  (described in detail herein with reference to  FIGS. 16-19 ). 
       FIGS. 6A-6B  show an exemplary embodiment of the window assembly  10  wherein the frame  32  is mounted on a chassis  42  in assembly. In these embodiments, the forward transition  18  is also mounted on the chassis  42  such that the frame  32  and forward transition  18  are aligned to accept the unified roof component (not shown). As a result, in these implementations are configured such that the roof component is disposed above the forward transition by way of the H section joint so as to prevent leakage and accommodate easier assembly. 
       FIGS. 7A-7D  depict various views of the frame  32 , modular window openings  38  and unified roof component  12  set into the body of the vehicle during assembly.  FIG. 7A  depicts the frame  32  assembled and attached to the chassis  42 .  FIG. 7B  depicts an interior view of the frame  32  with the unified roof component  12  mounted in place, and awaiting window installation. As is shown in  FIG. 7C , the modular window openings  38  fit around the frame&#39;s cage tubes.  FIG. 7D  depicts an exemplary embodiment comprising a retainer, or “inner cap”  44  to lock the modular windows in place. 
       FIG. 8  shows yet another view of the forward transition  18  installed on the chassis  42 . In this embodiment, modular window units  14  have been installed on the frame  32  such that they overlap the lower sidewall skin  46 . In these embodiments, the fiberglass skin  46  may be coupled to the window units as described in reference to  FIG. 19 . 
       FIGS. 9A-9B  depict yet further views of the unified roof component  12 . In certain embodiments, the unified roof component  12  installed on top of the chassis  42  in direct contact with the forward transition  18  and modular window units  14 , and apart from the lower sidewall fiberglass skin  46 , as described in reference to  FIGS. 16-19 . The unified roof component  12  is then clamped into place.  FIG. 9A  shows the unified roof component  12  before being mounted on the chassis, while  FIG. 9B  depicts the roof mounted on the chassis  42  but not yet clamped into place. In certain embodiments, adhesive is also employed to affix the unified roof component to the frame bows or roll cage. 
       FIG. 10  illustrates a cross section of one embodiment of the window assembly  10  showing the unified roof component  12  transition joint with the forward transition  18 , comprising the H section  16 . In certain exemplary embodiments, these H Sections  16  are extrusions which comprise upper  50  and lower  52  internal flanges, further comprising an upper outer flange  50 A, a upper inner flange  50 B, a lower outer flange  52 A, and a lower inner flange  52 B. In these embodiments, the various flanges  50 A,  52 A,  50 B,  52 B of the H sections  16  may comprise excess clearance around the forward transition  18 , such that a wedged shaped member (shown in  FIG. 11 ) may be inserted between the inside surface of the forward transition  18  or unified roof component  12  and the inside surface of the H Section flange  50 ,  52  thus forcing the transition or component to be tightly flush with the outer flanges  50 A,  52 A. In these embodiments, the outer flanges  50 A,  52 A may also be relatively shorter than the internal flanges  50 B,  52 B so as to allow any water infiltration to exit on the external side. In the embodiment shown in  FIG. 10 , a vinyl “wedge” insert may also be installed, which is described in reference to  FIGS. 11-12 . 
     In the embodiments of  FIGS. 11-13 , a pair of “wedge” inserts  54 ,  56  are shown, which (as described above) can be driven on the inside of the H section  16  between the unified roof component  12  or the forward transition  18  and the upper  50 B or lower  52 B internal flanges of the H Section  16 , respectively. In certain exemplary embodiments, stepped ridges on the inside surface of the internal flanges of the H-section can be utilized to increase the frictional resistance of the wedge shaped member, such that it is more difficult to remove or dislodge. In certain embodiments, these wedge shaped members  54 ,  56  may be comprised of rubber, vinyl, or some other material. In various embodiments, hook type features can be utilized on the internal flanges  50 B,  52 B of the H section, thus allowing the use of pliers or a similar tool to aid in providing additional force when inserting or replacing the wedge  54 ,  56 . 
       FIG. 14  depicts the H Section fitted between the unified roof component  12  and forward transition  18  on a vehicle.  FIG. 15  depicts an internal view of the vehicle showing the H Section  16  fitted between the unified roof component  12  and forward transition  18 . In certain embodiments, a combination of screws and/or adhesives may be used to strengthen the joint. Other implementations and embodiments are of course possible. 
     Turning to the window units in greater detail, in certain exemplary embodiments of the window assembly  10  shown in  FIGS. 16-19 , a key aspect involves modular window units that can be assembled separately from the vehicle and then installed easily. In these embodiments, the modular window units  100  can be installed on the frame, mounted between the sidewall skin and unified roof component. In certain embodiments, the window assembly comprises similar extrusions to those used in coordination with the fiberglass transition which may be specifically adapted to accommodate easy installation and removal of the window units. In certain embodiments, these extrusions are components of these modular window frames or modular window openings. 
     In certain embodiments, U-shape vertical extrusions can be utilized to allow the window assembly  100  to be placed onto the vehicle body frame, encapsulating the frame with sufficient clearance for the application of adhesives bonding the window frame to the vehicle frame structure, as discussed herein. 
     As shown in  FIG. 16 , certain embodiments generally comprise a modular window assembly  100  further comprising top  102  and bottom  104  window joints adjoining the assembly  100  and the unified roof component  106  and skin  110 , respectively. In the embodiment shown in  FIGS. 16-19 , each assembly also comprises one or more window panes  112 ,  114 , separated by a mullion  116 . In certain embodiments, and as also described herein, flat panel glass is installed with automotive urethane. Other implementations and embodiments are of course possible. 
     In certain exemplary embodiments, at least one of the windows is a tipout window pane  112 . In these embodiments the top window joint  102  comprises a tipout window hinge  108 . In certain escape window assemblies, the entire modular window assembly  100  can swing out, though in typical exemplary embodiments the top pane  112  is the tipout pane. In certain exemplary embodiments of the window assembly, bonded glass is utilized to improve the strength of the windows and decrease interior noise. 
       FIG. 17  shows a detailed view of the top window joint  102 . Exemplary embodiments may also comprise a hinge feature  108  as part of the top window extrusion, thus allowing addition of hinged vent or escape windows. Certain embodiments further comprise a clamping extrusion  118 , a top window extrusion  122 , and at least one window seal  124 . As shown in  FIG. 16 , in these embodiments, the clamping extrusion  118  and tipout window hinge  108  allow for easy placement and removal of the window assembly  100 . As is shown in detail in  FIG. 17 , the hinge  108  comprises a fixed pivot region  108 A and moving D-flange  108 B. As would be apparent to one of skill in the art, many other configurations are possible. 
     As shown in detail in  FIG. 17 , in certain embodiments, the top window extrusion  122  comprises an upper window flange  126  on the top edge of the window assembly which acts as a retainer for the inner roof skin  106  of the vehicle. In certain embodiments, the clamping extrusion  118  is mounted externally to the upper window flange  126  located on the top edge of the window assembly and top window extrusion  122  to allow a vehicle roof flange  106  to overlap, thus providing a shingle effect for water infiltration resistance, as is shown in  FIG. 17 . 
     In certain embodiments, the top flange has a ledge  122 A to position the vehicle roof flange in the correct position. In various embodiments, the top window extrusion  122  may be of sufficient thickness to allow threaded fasteners to be added to hold a clamping extrusion  118  tight to the vehicle roof flange  106  by way of the entry points  122 B,  122 C, thus clamping the roof flange  106  between the top window flange  126  and the clamping extrusion  118 . In certain embodiments, the clamping extrusion may have a further recessed area  118 A,  118 B where screws are used, thus allowing later application of a plastic strip into the recesses  118 A,  118 B to cover the screw heads to improve leak resistance and appearance, as would be apparent to one of skill in the art. 
       FIG. 18  shows a detailed cross-section of the mullion  116  set between the panes  112 ,  114 . In certain embodiments, the panes  112 ,  114  may be various affixed to the mullion  116  by way of a variety of seals  128 ,  130 . Various embodiments may further comprise additional features to facilitate the tipping out of the top pane  112 , including a latching mechanism and linkage (not shown) operationally coupled to the pane  112  and frame so as to facilitate limited opening of the pane from the hinge  108 . Various threaded fastener openings  132 ,  134  may also be provided which may provide anchoring means for the linkage and latch assembly, as would be apparent to one of skill in the art. 
     As shown in  FIG. 19 , in certain embodiments the window assembly also comprises a lower window extrusion  136  comprising a lower window flange  136 A which couples with the sidewall  110 . This extended flange  136 A allows overlap with the vehicle skin below the window providing a shingle effect for water infiltration resistance. An adhesive window seal  138  may also be utilized to affix a window pane  114  to the lower window extrusion  136 . In embodiments featuring an escape window, a seal may be utilized, while adhesive can be used in other tipping windows. A fastener opening  140  can also be provided for attachment. Certain embodiments also utilize an aluminum angle which attaches to the window and provides a trim cover capable covers the sidewall gap between the sidewall (not shown). 
     As shown in  FIG. 20 , in certain embodiments, the window panes  114 ,  114  are set in vertical window extrusions and covered with inner caps  44 . These inner caps (also shown in  FIGS. 7B-7D ) may be attached to the vertical window extrusion and act to enclose  34 A the steel vertical roll cage tube. In certain embodiments, the inner caps  44  may also be utilized to attach to the vertical window extrusions  114 A on the inside surface by way of an inner cap  44 , thus encapsulating the vertical window extrusion  114 A holding the panes  114 ,  114  in position while any adhesives cure and providing additional mechanical strength and improving the appearance of the window assembly from within the vehicle. Certain embodiments comprise one or more slots as a part of the vertical window extrusions and incorporate saw tooth type surfaces  252  designed to allow screws to be used to attach the inner cap  44 . In certain embodiments, the inner cap may be about 0.09″ thick and 3.2″ wide. Other implementations and embodiments are of course possible. 
       FIG. 21  shows the transition  200  from the H section  16  of the forward transition region  18  to the window assembly  14  region joint  102 . The H section  16  region couples with the top window joint  102  at a unified joint  200  and may further comprise an overlap system  202 , in which the unified roof component  12  overlaps the window assembly  100  which in turn overlaps the sidewall (not shown). A similar window assembly overlap system  204  may be present above the window assembly, as described in relation to the clamping extrusion  118  in  FIG. 17 . 
     Although the present invention has been described with reference to preferred embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.