Patent ID: 12196033

DETAILED DESCRIPTION

FIG.1illustrates an example of a door lite frame system10including a modular frame20and a modular frame30. The modular frame20is coupled to a plurality of male alignment members40and a plurality of male interlocking members50, each adjacent to a respective male alignment member40. A male alignment member40can include a rectangular shaft extending outward from the modular frame20. A male interlocking member50can include a rectangular shaft extending outward from the modular frame20and a plurality of arms55extending away from the rectangular shaft toward the respective male alignment member40. A male alignment member40and a respective male interlocking member50can together be referred to as a male alignment and interlocking member. The modular frame30is coupled to a plurality of female alignment members60, each female alignment member60including a plurality of teeth65coupled to a first side of a hollow rectangular shaft opposite a second side of the hollow rectangular shaft. In some embodiments, the modular frame20can be identical to the modular frame30, can have dimensions matching those of the modular frame30, or can be fabricated from the same mold as used to fabricate the modular frame30.

FIG.2illustrates a corner portion of the modular frame20and two male alignment and interlocking members in greater detail.FIG.3illustrates a corner portion of the modular frame30and two of the female alignment members60in greater detail. The female alignment members60can include hollow elements which can be configured to receive respective male alignment members40in either one of two different orientations. Further, the male and female alignment members40,60, can be positioned around the modular frames20,30, respectively, such that as the modular frames20,30are brought toward one another, each male alignment member40enters a respective female alignment member60.

For example, the modular frame20can be aligned with the modular frame30in a first aligned configuration such that the modular frames20,30can be brought toward one another until the male alignment members40enter respective female alignment members60such that the arms55of each male alignment member40are adjacent the second side of a respective female alignment member60, such that the teeth65do not engage the arms55. Such an arrangement can be referred to as an unlocked, shipping arrangement because the modular frame20and the modular frame30are not locked to one another and can be pulled laterally apart from one another. In such an arrangement, engagement of the male and female alignment members40,60can align the modular frames20,30with one another, such as during transportation of the frame system10to an installation location.

As another example, the modular frame20can be aligned with the modular frame30in a second aligned configuration such that the modular frames20,30can be brought toward one another until the male alignment members40enter respective female alignment members60such that the arms55of each male alignment member40are adjacent the first side of a respective female alignment member60, such that the teeth65do engage the arms55. Such an arrangement is illustrated inFIG.4and in greater detail inFIG.5, and can be referred to as a locked, installed arrangement because the modular frame20and the modular frame30are locked to one another and cannot be pulled laterally apart from one another without breaking one or more components of the frame system10. In such an arrangement, engagement of the male and female alignment members40,60can align the modular frames20,30with one another, and engagement of the teeth65with the arms55can lock the modular frames20,30to one another.

In some embodiments, the modular frames20,30can be progressively brought toward one another and the arms55can progressively engage the teeth65to progressively lock the modular frames20,30to one another. Thus, in different implementations, the modular frames20,30can be locked together in the locked, installed arrangement with different distances between the modular frames20,30. The different distances between the modular frames20,30allow glass or glazing of different thicknesses to be held in place between an inner surface90of the modular frame20and an inner surface95of the modular frame30, and can likewise allow the frame system10to be used with doors or other structures of different thicknesses.

The frame system10can be configured such that the orientation of the modular frame20in the first aligned configuration is rotated 180° with respect to the modular frame30from the orientation of the modular frame20in the second aligned configuration. Thus, a method of installing the frame system10can include fabricating the individual components of the system10, coupling the components to one another as shown inFIG.1, shipping the frame system10in the unlocked, shipping arrangement to an installation location, pulling the modular frames20,30laterally away from one another, and coupling the modular frames20,30to one another in the locked, installed arrangement with a window between them. For example, a piece of material such as glass or glazing can be held in place between the inner surface90of the modular frame20and the inner surface95of the modular frame30.

As illustrated inFIGS.1-5, a first modular frame20of the system10can be coupled to male alignment members40and male interlocking members50but not to female alignment members60, and a second modular frame30of the system10can be coupled to female alignment members60but not to male alignment members40or male interlocking members50. In other embodiments, however, a first modular frame of a frame system can be coupled to one or more male alignment members40, one or more male interlocking members50, and one or more female alignment members60, and a second modular frame of the frame system can be coupled to one or more male alignment members40, one or more male interlocking members50, and one or more female alignment members60.

In some specific embodiments, a first modular frame of a frame system can be coupled to one or more male alignment members40, one or more male interlocking members50, and one or more female alignment members60, and an identical second modular frame of the frame system can be identically coupled to one or more male alignment members40, one or more male interlocking members50, and one or more female alignment members60, such that the first modular frame and the members coupled thereto are identical to the second modular frame and the members coupled thereto. In some embodiments, the positions of the male alignment members40, male interlocking members50, and female alignment members60on the first modular frame can correspond to those on the second modular frame such that the first and second modular frames can be coupled to one another in an unlocked, shipping arrangement, and in a locked, installed arrangement as described above.

As illustrated inFIGS.1-5, a first modular frame20of the system10can be coupled to male alignment and interlocking members facing the same direction, i.e., such that the male alignment members40and the male interlocking members50alternate along each side of the modular frame20. Similarly, the second modular frame30of the system10can be coupled to female alignment members60facing the same direction, i.e., such that the first side of each female alignment member60faces the second side of an adjacent female alignment member60or such that the first side of each female alignment member60does not face a first side of an adjacent female alignment member60. In other embodiments, however, a first modular frame of a frame system can be coupled to male alignment and interlocking members facing in different or alternating directions. Similarly, a second modular frame of the frame system can be coupled to one or more female alignment members60facing in different or alternating directions. In such embodiments, the positions and orientations of the male alignment members40, male interlocking members50, and female alignment members60on the first modular frame can correspond to those on the second modular frame such that the first and second modular frames can be coupled to one another in an unlocked, shipping arrangement, and in a locked, installed arrangement as described above.

It has been found that a convenient and economical method of fabricating the components of the frame system10is doing so modularly. More specifically, it has been found that fabricating a single integral component that includes both of the modular frame20and the male alignment and interlocking member or a single integral component that includes both of the modular frame30and the female alignment member60can be unnecessarily expensive, for several reasons. First, injection molding of such integral members can use complex molds and one or more side pulls, which can increase the cost of the molds and fabrication process. Second, two separate molds are often used—one for the integral component that includes the modular frame20and the male alignment and interlocking member and another for the integral component that includes the modular frame30and the female alignment member60—in effect doubling the cost of the already expensive molds. Third, two of such expensive molds are used for each size of door lite to be fabricated. Thus, to manufacture a 24″×36″ window, a 28″×54″ window, and a 34″×46″ window, six expensive molds may be used. In contrast, it has been found that modular fabrication of components of door lite systems can reduce mold costs by greater than 50%, and in some cases, even up to about 75%.

In some embodiments, the modular frame20can be formed without the plurality of male alignment members40and without the plurality of male interlocking members50, and the modular frame30can be formed without the plurality of female alignment members60. The plurality of male alignment members40, the plurality of male interlocking members50, and the plurality of female alignment members60can be formed separately from the other components of the frame system10. The plurality of male alignment members40and the plurality of male interlocking members50can then be coupled to the modular frame20, and the plurality of female alignment members60can be coupled to the modular frame30. The frame system10can then be shipped in the unlocked, shipping arrangement to an installation location, the modular frames20,30can be pulled laterally away from one another, and the modular frames20,30can then be coupled to one another in the locked, installed arrangement with a window between them.

In some cases, the modular frame20can be formed without the plurality of male alignment members40and without the plurality of male interlocking members50by injection molding acrylonitrile-butadiene-styrene (ABS) between no more than two opposed mold portions. In some cases, the modular frame30can be formed without the plurality of female alignment members60by injection molding acrylonitrile-butadiene-styrene (ABS) between no more than two opposed mold portions. In some cases, the plurality of male alignment members40, the plurality of male interlocking members50, and the plurality of female alignment members60can each be formed separately from the other components of the frame system10by injection molding acrylonitrile-butadiene-styrene (ABS) between no more than two opposed mold portions. In some cases, each male alignment member40can be formed integrally with a respective male interlocking member50but separately from the other components of the frame system10by injection molding acrylonitrile-butadiene-styrene (ABS) between no more than two opposed mold portions to form a male alignment and interlocking member.

FIG.6Aillustrates a cross-sectional side view,FIG.6Ban end view,FIG.6Ca side view,FIG.6Da top view,FIG.6Ea first perspective view, andFIG.6Fa second perspective view of one embodiment of a male alignment and interlocking member100including a male alignment member42similar to male alignment member40and a male interlocking member52similar to male interlocking member50that was formed separately from the other components of the frame system of which it forms a part.FIG.7Aillustrates a cross-sectional side view,FIG.7Ban end view,FIG.7Ca side view,FIG.7Da top view,FIG.7Ea first perspective view, andFIG.7Fa second perspective view of one embodiment of a female alignment member62similar to female alignment member60that was formed separately from the other components of the frame system of which it forms a part.FIG.8Aillustrates a perspective view,FIG.8Ba side view,FIG.8Can end view, andFIG.8Da top view of one embodiment of a spacer element80that was formed separately from the other components of the frame system of which it forms a part.

The dimensions provided inFIGS.6A-6F,7A-7F, and8A-8Dhave units of millimeters (as do the dimensions provided in all of the Figures), and are examples of dimensions that have been found to be suitable. These dimensions are not intended to limit the scope of the disclosure. As illustrated, a length of the male alignment and interlocking member100can be the same as the combined length of the female alignment member62and the spacer element80, such that the male alignment and interlocking member100can be mounted interchangeably with the combination of a female alignment member62and a spacer element80to another portion of a frame system such as a recess of a modular frame.

FIG.9illustrates a perspective view,FIG.10a top view,FIG.11a side view,FIG.12a cross-sectional side view taken along line A-A shown inFIG.10,FIG.13an end view,FIG.14a first cross-sectional end view taken along line B-B shown inFIG.10, andFIG.15a second cross-sectional end view taken along line C-C shown inFIG.10of a first embodiment of a modular frame110formed separately from the other components of the frame system of which it forms a part. Modular frame110can be similar to modular frame20or modular frame30. In some cases, the modular frame110can be formed by injection molding acrylonitrile-butadiene-styrene (ABS) between no more than two opposed mold portions.

The modular frame110includes a rectangular frame112with a central rectangular opening114. The rectangular frame112includes a plurality of recesses116which can form seats into which a male alignment and interlocking member similar to male alignment and interlocking member100, a female alignment member similar to female alignment member60, and/or a spacer element similar to spacer element80can be mounted. In some cases, a first modular frame110can be coupled to a plurality of such male alignment and interlocking members (i.e., the male alignment and interlocking members can be mounted within the recesses116of the first modular frame110) and a second modular frame110can be coupled to a plurality of such female alignment members and respective spacer elements (i.e., the female alignment members and respective spacer elements can be mounted within the recesses116of the second modular frame110). The first and second modular frames110, coupled to such components, can form a door lite frame system similar to door lite frame system10.

The modular frame110is illustrated having certain dimensions, and the modular frame110can have various alternative dimensions. In some cases, the modular frame110can have a larger overall length or width, so as to form a part of a larger door lite system, while other dimensions of the modular frame110remain the same as those illustrated. In other cases, the modular frame110can have a smaller overall length or width, so as to form a part of a smaller door lite system, while other dimensions of the modular frame110remain the same as those illustrated. In either case, a male alignment member, a male interlocking member, a male alignment and interlocking member, a female alignment member, and/or a spacer element can be coupled to the modular frame110regardless of its overall length and width.

FIG.16illustrates a portion of a top view,FIG.17a first cross-sectional end view taken along line1-1shown inFIG.16, andFIG.18a second cross-sectional end view taken along line2-2shown inFIG.16of a second embodiment of a modular frame120formed separately from the other components of the frame system of which it forms a part. The modular frame120can be similar to modular frame20or modular frame30. In some cases, the modular frame120can be formed by injection molding acrylonitrile-butadiene-styrene (ABS) between no more than two opposed mold portions.

The modular frame120includes a rectangular frame122with a central rectangular opening124. The rectangular frame122includes a plurality of recesses126which can form seats into which a male alignment and interlocking member similar to male alignment and interlocking member100, a female alignment member similar to female alignment member60, and/or a spacer element similar to spacer element80can be mounted. In some cases, a first modular frame120can be coupled to a plurality of such male alignment and interlocking members (i.e., the male alignment and interlocking members can be mounted within the recesses126of the first modular frame120) and a second modular frame120can be coupled to a plurality of such female alignment members and respective spacer elements (i.e., the female alignment members and respective spacer elements can be mounted within the recesses126of the second modular frame120). The first and second modular frames120, coupled to such components, can form a door lite frame system similar to door lite frame system10.

The modular frame120is illustrated having certain dimensions, and the modular frame120can have various alternative dimensions. In some cases, the modular frame120can have a larger overall length or width, so as to form a part of a larger door lite system, while other dimensions of the modular frame120remain the same as those illustrated. In other cases, the modular frame120can have a smaller overall length or width, so as to form a part of a smaller door lite system, while other dimensions of the modular frame120remain the same as those illustrated. In either case, a male alignment member, a male interlocking member, a male alignment and interlocking member, a female alignment member, and/or a spacer element can be coupled to the modular frame120regardless of its overall length and width.

FIG.19illustrates a top perspective view,FIG.20a bottom perspective view,FIG.21a top view,FIG.22a cross-sectional end view taken along line A-A shown inFIG.21, andFIG.23a cross-sectional end view taken along line B-B shown inFIG.21of a third embodiment of a modular frame130formed separately from the other components of the frame system of which it forms a part. Modular frame130can be similar to modular frame20or modular frame30. In some cases, the modular frame130can be formed by injection molding acrylonitrile-butadiene-styrene (ABS) between no more than two opposed mold portions.

The modular frame130includes a rectangular frame132with a central rectangular opening134. The rectangular frame132includes a plurality of recesses136which can form seats into which a male alignment and interlocking member similar to male alignment and interlocking member100, a female alignment member similar to female alignment member60, and/or a spacer element similar to spacer element80can be mounted. In some cases, a first modular frame130can be coupled to a plurality of such male alignment and interlocking members (i.e., the male alignment and interlocking members can be mounted within the recesses136of the first modular frame130) and a second modular frame130can be coupled to a plurality of such female alignment members and respective spacer elements (i.e., the female alignment members and respective spacer elements can be mounted within the recesses136of the second modular frame130). The first and second modular frames130, coupled to such components, can form a door lite frame system similar to door lite frame system10.

The modular frame130is illustrated having certain dimensions, and the modular frame130can have various alternative dimensions. In some cases, the modular frame130can have a larger overall length or width, so as to form a part of a larger door lite system, while other dimensions of the modular frame130remain the same as those illustrated. In other cases, the modular frame130can have a smaller overall length or width, so as to form a part of a smaller door lite system, while other dimensions of the modular frame130remain the same as those illustrated. In either case, a male alignment member, a male interlocking member, a male alignment and interlocking member, a female alignment member, and/or a spacer element can be coupled to the modular frame130regardless of its overall length and width.

FIG.24illustrates a portion of a top view,FIG.25a first cross-sectional end view taken along line A-A shown inFIG.24, andFIG.26a larger view of a portion ofFIG.25of a fourth embodiment of a modular frame140formed separately from the other components of the frame system of which it forms a part. Modular frame140can be similar to modular frame20or modular frame30. In some cases, the modular frame140can be formed by injection molding acrylonitrile-butadiene-styrene (ABS) between no more than two opposed mold portions.

The modular frame140includes a rectangular frame142with a central rectangular opening144. The rectangular frame142includes a plurality of recesses146which can form seats into which a male alignment and interlocking member similar to male alignment and interlocking member100, a female alignment member similar to female alignment member60, and/or a spacer element similar to spacer element80can be mounted. In some cases, a first modular frame140can be coupled to a plurality of such male alignment and interlocking members (i.e., the male alignment and interlocking members can be mounted within the recesses146of the first modular frame140) and a second modular frame140can be coupled to a plurality of such female alignment members and respective spacer elements (i.e., the female alignment members and respective spacer elements can be mounted within the recesses146of the second modular frame140). The first and second modular frames140, coupled to such components, can form a door lite frame system similar to door lite frame system10.

The modular frame140is illustrated having certain dimensions, and the modular frame140can have various alternative dimensions. In some cases, the modular frame140can have a larger overall length or width, so as to form a part of a larger door lite system, while other dimensions of the modular frame140remain the same as those illustrated. In other cases, the modular frame140can have a smaller overall length or width, so as to form a part of a smaller door lite system, while other dimensions of the modular frame140remain the same as those illustrated. In either case, a male alignment member, a male interlocking member, a male alignment and interlocking member, a female alignment member, and/or a spacer element can be coupled to the modular frame140regardless of its overall length and width.

FIG.27illustrates a top view,FIG.28a cross-sectional side view along line A-A shown inFIG.27,FIG.29a cross-sectional end view along line B-B shown inFIG.27, andFIG.30an end view of a mold system150for forming a modular frame for use in a door lite frame system. The modular frame can be formed between a first, bottom mold plate152and a second, top mold plate154opposed to the first mold plate152, such as within a void or cavity156defined between the mold plates152,154.FIG.31illustrates a three-dimensional representation of the mold system150, andFIG.32illustrates an exploded three-dimensional representation of the mold system150. In some cases, the first mold plate152or the second mold plate154can have surface patterns formed thereon such that the modular frame formed in the mold system150has corresponding surface patterns.

FIG.33illustrates that a modular frame180similar to one of modular frames110,120,130, or140can include a plurality of locator tabs160positioned within its recess182, similar to one of the recesses116,126,136, or146. The locator tabs160can protrude outward from a surface162of the modular frame180to which other components will be mounted. The locator tabs160can be positioned within the recess182to guide a male alignment and interlocking member or a female alignment member and a spacer element into a desired location within the recess182.FIG.34illustrates that the locator tabs160can be used in combination with an adhesive such as an ABS structural adhesive164. In some cases, the ABS structural adhesive164can be used without the locator tabs160. In some cases, the ABS structural adhesive164can provide a bond that is at least as strong as, or stronger than, solid ABS material.

FIG.35illustrates that a modular frame184similar to one of modular frames110,120,130, or140can include a plurality of angle elements166such as steel angles positioned within its recess186, similar to one of the recesses116,126,136, or146. The angle elements166can include a bottom leg portion168and a top leg portion170coupled to the bottom leg portion168at a 90° angle. The angle elements166can be formed integrally with the modular frame184or can be formed separately from the modular frame184and coupled thereto, such as with an adhesive positioned between the bottom leg portions168and the modular frame184. Each top leg portion170can function in a manner similar to the locator tabs160, as described above, and can also include a hole172for receiving a fastener such as a screw174. Once components, such as a male alignment and interlocking member, are seated within the recess186between two top leg portions170, screws174can be screwed through the top leg portions170and into the components to secure them to the modular frame184. The angle elements166can be used in combination with an adhesive such as an ABS structural adhesive, as shown inFIG.34, or without such an adhesive. In some cases, the angle elements166and screws174can provide a bond that is at least as strong as, or stronger than, solid ABS material.

In some cases, modular door lite components in accordance with the above description can be provided in systems or kits. For example, a system of modular door lite components can include two modular frames similar to modular frames20,30,110,120,130, and/or140, a male alignment and interlocking member similar to male alignment and interlocking member100, a female alignment member similar to female alignment member60, and a spacer element similar to spacer element80. A door lite system can be assembled from these components.

As another example, a system of modular door lite components can include two modular frames each having a first width and a first length, two modular frames each having a second width and a second length, two male alignment and interlocking members having the same dimensions as one another, two female alignment members having the same dimensions as one another, and two spacer elements having the same dimensions as one another. The first width can be larger or smaller than the second width, and the first length can be larger or smaller than the second length. Two door lite systems having different overall dimensions can be assembled from these components.

The modular door lite components described herein can be used to assemble door lites at less expense than previous door lite systems. The reduced expense can be attributed to at least the modular nature of the components and to reduced manufacturing costs associated with the elimination of side pulls and the use of no more than two opposed mold portions to form the components. The methods, systems, and devices described herein can be used to turn metal frames into energy efficient (thermal break) snap frames.

The various embodiments described above can be combined to provide further embodiments. All of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, including U.S. patent application Ser. No. 14/643,861, filed Mar. 10, 2015, are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.

These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.