Abstract:
A method for producing a window assembly that comprises providing a glass pane having an outer surface, and providing a plurality of frame assemblies that cooperate with one another to surround the glass pane. The method also includes covering at least a select one of the frame assemblies with at least one cover member having an outer surface. The method further includes covering at least a portion of the outer surface of the glass pane and at least a portion of the outer surface of the at least one cover member with a protective member such that the at least one cover member and the protective member are adapted to be removed from the window assembly subsequent to installation of the window assembly.

Description:
[0001]     This application claims the benefit of U.S. Provisional Application No. 60/643,670, filed Jan. 13, 2005, entitled WINDOW PROTECTION ASSEMBLY, which is hereby incorporated herein by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates generally to a method for protecting window assemblies, and in particular relates to a method for protecting the glass panes and frame assemblies of a window assembly prior and subsequent to installation of the window assembly into an associated building structure.  
         [0003]     Window assemblies typically include an outer frame surrounding a plurality of window panes. The outer frame typically includes an aesthetic outer surface, while each window pane includes a viewable area of which needs to be free from viewing obstructions, such as scratches, and the like. Window assemblies are typically constructed offsite with respect to the building site, and are installed in an appropriate building structure as a single unit. Once installed, the window assembly is subject to the construction environment, and possible damage, including scratching, marring, etc., of the outer aesthetic surface of the frame assembly of the window panes.  
         [0004]     Heretofore, the outer aesthetic surface of the outer frame and the surfaces of the window pane have been protected during shipping by various packaging arrangements and materials. However, these packaging arrangements and materials are removed prior to installation of the window within the building structure. Further, the outer surfaces of the associated glass panes have been protected by covering the glass panes with a protective film, however, these films protect only the glass pane, and are typically difficult to remove from the glass pane once the window assembly is installed within the building structure.  
         [0005]     A window protection assembly is desired that protects an associated window assembly during shipping, installation of the window assembly into a building structure, and completion of the building structure subsequent to the installation of the window assembly therein. A window protection assembly is also desired that allows easy removal of such a protection assembly from an associated window assembly subsequent to the installation of the window assembly into the building structure.  
       SUMMARY OF THE INVENTION  
       [0006]     One aspect of the present invention is a method for producing a window assembly that comprises providing a glass pane having an outer surface, and providing a plurality of frame assemblies that cooperate with one another to surround the glass pane. The method also includes covering at least a select one of the frame assemblies with at least one cover member having an outer surface. The method further includes covering at least a portion of the outer surface of the glass pane and at least a portion of the outer surface of the at least one cover member with a protective member such that the at least one cover member and the protective member are adapted to be removed from the window assembly subsequent to installation of the window assembly.  
         [0007]     Another aspect of the present invention is a method for producing a window assembly that includes providing a pair of glass panes each having an outer surface, providing an inner frame assembly, and providing a plurality of outer frame assemblies that cooperate with one another in the inner frame assembly to surround the pair of glass panes, such that the inner frame assembly is located between the pair of glass panes. The method also includes covering the outer frame assemblies and the inner frame assembly with at least one cover member having an outer surface. The method further includes covering at least a portion of the outer surface of each of the glass panes and at least a portion of the outer surface of the at least one cover member with a protective coating, such that the at least one cover member and the protective coating are adapted to be removed from the window assemblies subsequent to installation of the window assembly.  
         [0008]     The present inventive window protection assembly protects an associated window assembly during shipping, installation of the window assembly into a building structure, and completion of the building structure subsequent to the installation of the window assembly therein. The window protection assembly further allows easy removal of such a protection assembly from an associated window assembly subsequent to the installation of the window assembly into the building structure and is particularly well adapted for the proposed use. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  is a perspective view of a window assembly and a window protection assembly embodying the present invention;  
         [0010]      FIG. 2  is a cross-sectional view of a pair of side frame assemblies and a center frame assembly of the window assembly, taken along the line II-II,  FIG. 1 ;  
         [0011]      FIG. 3  is a cross-sectional view of a head jamb assembly and a sill assembly of the window assembly, taken along the line III-III,  FIG. 1 ;  
         [0012]      FIG. 4  is a perspective view of a side jamb cover;  
         [0013]      FIG. 5  is an end view of the side jamb cover;  
         [0014]      FIG. 6  is a perspective view of a head jamb or sill cover;  
         [0015]      FIG. 7  is an end view of the head jamb or sill cover; and  
         [0016]      FIG. 8  is an end view of a mull cover. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0017]     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.  
         [0018]     The reference numeral  10  ( FIG. 1 ) generally designates a window assembly that includes a window protection assembly  11  embodying the present invention. The window assembly  10  includes side frame assemblies  12  ( FIG. 2 ), a center frame or mull assembly  14 , a top frame assembly  16  ( FIG. 3 ), a bottom frame assembly  18 , and window panes  13 . The window protection assembly  11  covers an outer surface of the frame assemblies  12 ,  14 ,  16 ,  18 , and an outer surface  20  of the window panes  13 , as described below.  
         [0019]     Each side frame assembly  12  includes a side jamb  22  and a side frame member  24 , each preferably constructed of wood, and adapted for relative movement therebetween, as is known in the art. Each side frame assembly  12  further includes a side frame cladding  26  having a first portion  28  that covers the side jamb  22  and a separate second portion  30  that covers the side frame member  24 . The first portion  28  includes an outwardly-extending rectangularly-shaped body portion  32  having an outwardly-disposed coupling channel  34  and an inwardly-facing abutment wall  36 . The first portion  28  also includes a C-shaped engagement portion  38  that engages the side jamb  22 , and an alignment leg  40  extending laterally therefrom and that is adapted to abut a portion of a building structure, thereby allowing proper alignment of the window assembly  10  with the building structure. The coupling channel  34  includes a plurality of engagement teeth  42  extending longitudinally therealong. The second portion  30  is C-shaped and includes a pair of legs  44  that engage a pair of channels  46  of the side frame member  24 , thereby securing the second portion  30  of the frame cladding  26  with the side frame member  24 . The second portion  30  further includes an inwardly-extending V-shaped leg  48  adapted to provide a gap  50  between the leg  48  and one of the window panes  13  within which a sealant is located.  
         [0020]     The center frame or mull assembly  14  is similar in construction to the side frame assemblies  12  in that the center frame assembly  14  includes a pair of assemblies similar to the side frame assemblies  12  oriented in a back-to-back relationship. Specifically, the center frame assembly  14  includes a pair of jambs  52  similar to side jambs  22 , a pair of frame members  54  similar to the side frame members  24 , and a pair of frame claddings  56  similar to the side frame claddings  26 . A center clip  58  includes a pair of engagement legs  60  that engage the coupling channel  62  of each frame cladding  56 .  
         [0021]     The top frame assembly  16  includes a head jamb  66  that aligns along the top of the window assembly  10 . The top frame assembly  16  further includes a top frame member  68 , a top frame cladding  70  having a first portion  72  and a second portion  74 , each constructed similarly to the side frame member  24 , the side frame cladding  26  and the first and second portions  28 ,  30 , respectively. The bottom frame assembly  18  includes a sill  76  that aligns along the bottom of the window assembly  10 . The bottom frame assembly  18  further includes a bottom frame member  78 , a bottom frame cladding  80  having a first portion  82  and a second portion  84 , each constructed similarly to the side frame member  24 , the side frame cladding  26  and the first and second portions  28 ,  30 , respectively.  
         [0022]     The window protection assembly  11  includes a pair of side jamb covers  86  ( FIGS. 4 and 5 ), a pair of head jamb covers and sill covers  88  ( FIGS. 6 and 7 ), and a mull cover  90 . Each side jamb cover  86  includes an angled body portion  92 , a top lip portion  94  extending outwardly from the body portion  92 , and a bottom lip portion  96  extending inwardly from the body portion  92 . The body portion  92 , the top lip portion  94  and the bottom lip portion  96  cooperate to form an outer surface  97 . Each side jamb cover  86  further includes a flexibly-resilient first engagement arm  98  extending inwardly from the top lip portion  94  and including a barbed end  100 . Each side jamb cover  86  further includes a second engagement arm  102  extending inwardly from the body portion  92  and including a barbed end  104 . Each of the sill covers and head jamb covers  88  are similar in construction to the side jamb covers  86 , with the major exception being the configuration of the associated lower lip of each. Each of the sill covers and head jamb covers  88  include a body portion  106 , a top lip portion  108  and a bottom lip portion  110  that cooperate to form an outer surface  112 . Each sill cover and head jamb cover  88  further includes a first engagement arm  114  extending inwardly from the top lip portion  108  and including a barbed end  116 , and a second engagement arm  118  extending inwardly from the body portion  106  and including a barbed end  120 . The mull cover  90  includes a pair of angular sidewalls  122 , a top wall  124  extending between and connecting the sidewalls  122  and a pair of bottom lip portions  126  extending outwardly from each of the sidewalls  122 . The sidewalls  122 , the top wall  124  and the bottom lip portions cooperate to form an outer surface  127 . The mull cover  90  further includes a pair of abutment legs  128  extending inwardly from the sidewalls  122  and each including a barbed end  130 . Preferably, each of the barbed ends  100 ,  104 ,  116 ,  120 ,  130  are constructed of a flexibly resilient material, such as Santoprene™, as available from Advanced Elastomer Systems of Akron, Ohio however, other materials suitable for such application may be utilized therefore. Moreover, the entire construction of each of the side jamb covers  86 , the sill and head jamb covers  88 , and the mull cover  90  may be made from a flexibly-resilient material.  
         [0023]     In assembly, the window panes  13 , the side frame assemblies  12 , the center frame assembly  14 , the top frame assembly  16  and the bottom frame assembly  18  are coupled in a manner that is known in the art to form the window assembly  10 . Subsequent to assembly of the window assembly  10 , the side jamb covers  86 , the sill covers and head jamb covers  88 , and the mull cover  90  are coupled with the window assembly  10 . Specifically, each of the side jamb covers  86  are coupled with the window assembly  10  such that each of the side jamb covers  86  covers a respective side frame assembly  12 . Each of the side jamb covers  86  are coupled to a respective side frame assembly  12  by inserting the first engagement arm  98  of the side jamb cover  86  into the coupling channel  34  of the first portion  28  of the side frame cladding  26  such that the barbed end  100  of the first engagement arm  98  engages the teeth  42  of the coupling channel  34 , and the end  104  of the second engagement arm  102  frictionally engages the body portion of the first portion  28  of the side frame cladding  26 . The sill cover and head jamb cover  88  are coupled with the top frame assembly  16  and the bottom frame assembly  18  in a like manner. The mull cover  90  is coupled with the center frame assembly  14  by pressing the mull cover  90  inwardly such that each end  130  of the abutment legs  128  of the mull cover  90  frictionally engage the body portion of the first portion of the frame cladding  56 .  
         [0024]     The window protection assembly  11  is then completed by spraying a thin protective film  132  over the window assembly  10 , such that the protective film  132  covers and adheres to the outer surface  97  of the side jamb covers  86 , the outer surface  112  of each of the sill covers and head jamb covers  88 , the outer surface  127  of the cover  90 , and the outer surface  20  of the window panes  13 . The protective film  132  is preferably sprayed upon the outer surfaces  97 ,  112 ,  127  as described above by an automated system incorporated within a production line, but may also be applied to the outer surfaces  97 ,  112 ,  127  by hand. The protective film  132  is preferably constructed of water-based polymer, for example Temprotec™, as available from Tempro Tec, Inc. of Canada, however, other suitable materials may be utilized. Alternatively, the protective film  132  is applied via a roll-on type method, or is supplied in a roll sheet form which is applied to the assembly.  
         [0025]     Subsequent to the assembly of the window assembly  10  and the window protection assembly  11 , the window assembly  10  is packaged for delivery to a building construction site where the window assembly  10  is placed into the building structure with the window protection assembly  11  still coupled with the window assembly  10 . Subsequent to installation, the window protection assembly  11  is removed from the window assembly  10  by grasping each of the covers  86 ,  88 ,  90 , unsnapping the covers  86 ,  88 ,  90  from the frame assemblies  12 ,  14 ,  16 ,  18 , and peeling the protective film  132  from the outer surface  20  of each window pane  13 .  
         [0026]     In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.