U.S. patent application number 10/939347 was filed with the patent office on 2005-02-10 for reinforcing structure for a window frame system.
Invention is credited to LaSusa, Frank.
Application Number | 20050028480 10/939347 |
Document ID | / |
Family ID | 36060670 |
Filed Date | 2005-02-10 |
United States Patent
Application |
20050028480 |
Kind Code |
A1 |
LaSusa, Frank |
February 10, 2005 |
Reinforcing structure for a window frame system
Abstract
A method of reinforcing and sealing a composite frame is
provided. The method includes receiving material for processing,
the material having surfaces defining at least one continuous
channel therein; cutting the received material to a desired length;
forming at least one notch in the material by cutting the material
at certain angles thereby defining a pair of notch surfaces;
placing reinforcing structures and sealing measures within at least
a portion of the channel; and folding the material at the notch so
that the notch surfaces are in abutting relation and moving the
ends to be in abutting relating to define a closed frame. The
reinforcing and sealing structure increases the structural
integrity of the frame and provides a seal tight exterior as well
as an aesthetically pleasing finished product.
Inventors: |
LaSusa, Frank; (Clinton,
UT) |
Correspondence
Address: |
MANELLI DENISON & SELTER
2000 M STREET NW SUITE 700
WASHINGTON
DC
20036-3307
US
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Family ID: |
36060670 |
Appl. No.: |
10/939347 |
Filed: |
September 14, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10939347 |
Sep 14, 2004 |
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10175021 |
Jun 18, 2002 |
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10175021 |
Jun 18, 2002 |
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09679220 |
Oct 3, 2000 |
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6678934 |
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60157625 |
Oct 4, 1999 |
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Current U.S.
Class: |
52/741.1 |
Current CPC
Class: |
E06B 3/67308 20130101;
B29L 2031/778 20130101; B29C 53/066 20130101; E06B 3/9649 20130101;
B23P 15/00 20130101; E06B 3/9641 20130101; E06B 3/96 20130101; B29L
2012/00 20130101 |
Class at
Publication: |
052/741.1 |
International
Class: |
E04B 001/00 |
Claims
What is claimed is:
1. A method of reinforcing a composite frame, the method including:
receiving material for processing, the material having surfaces
defining at least one continuous channel therein, cutting the
received material to a desired length, forming at least one notch
in the material by cutting the material at certain angles thereby
defining a pair of notch surfaces, placing reinforcing structure
within at least a portion of the channel, and thereafter, folding
the material at the notch so that the notch surfaces are in
abutting relation and moving the ends to be in abutting relating to
define a closed frame with the reinforcing structure, disposed
within the channel in the closed frame, providing reinforcement to
the frame.
2. The method of claim 1, wherein the reinforcing structure has a
main body and a cable structure having first and second ends, the
first end being coupled with the main body, the placing step
including securing the main body within the channel at a certain
location and orienting the cable structure to extend from the
certain location within the entire continuous channel and back
generally to the certain location, and securing the second end to
the main body so that the cable structure provides compression to
the frame.
3. The method of claim 2, wherein the second end of the cable
structure is adjustably coupled with the main body to control
tension of the cable structure, the method including adjustably
securing the second end to the main body to control tension of the
cable structure.
4. The method of claim 1, wherein the frame is composed of
vinyl.
5. The method of claim 1, wherein the frame is a window frame.
6. The method of claim 1, wherein a corner is formed by the
abutting ends and another corner is formed at the notch by the
abutting notch surfaces, and wherein the placing step includes
placing a reinforcing structure at each said corner.
7. The method of claim 6, wherein the reinforcing structure at the
corner formed by the notch is a mechanism constructed and arranged
to maintain the notch surfaces in abutting relation.
8. The method of claim 7, wherein the mechanism includes a pair of
pivoting elements, such that when the reinforcing structure is
placed at the corner formed by the notch, the elements are in an
inoperative position, and during the folding step, the elements
pivot to an operative position maintaining the notch surfaces in
abutting relation.
9. The method of claim 8, wherein each member has a hollow core
defining a conduit through which a sealant can be injected to
application points of the frame.
10. The method of claim 8, wherein the mechanism includes ratchet
structure to lock the elements in the operative position.
11. The method of claim 6, wherein the reinforcing structure
includes a pair of members at each corner, one member of each pair
being disposed transversely with respect to the other member of the
pair, a locking member securing the members together in abutting
relation.
12. The method of claim 6, wherein the frame is a window frame
having a glass tower, the channel being defined in the glass tower,
the reinforcing structure including a generally L-shaped member,
the placing step including placing at least a portion of an
L-shaped member in the channel of the glass tower at each
corner.
13. A reinforcing structure for a composite frame, the frame
defining a closed structure, the closed structure having an
interior periphery defining a portion of a continuous channel in
the frame, the reinforcing structure comprising: a main body
constructed and arranged to be secured within the channel at a
certain location, and a cable structure having first and second
ends, the first end being coupled with the main body, and the cable
structure being of a length sufficient to extend from the certain
location about the periphery and within the continuous channel and
back generally to the certain location so that the second end of
the cable structure can be secured to the main body so that the
cable structure can provide compression to the frame.
14. The reinforcing structure of claim 13, wherein the second end
of the cable structure is constructed and arranged to be adjustably
coupled with the main body to control tension of the cable
structure.
15. The reinforcing structure of claim 14, wherein the second end
of the cable structure and the main body are constructed and
arranged to be in adjustable treaded engagement.
16. The reinforcing structure of claim 14, wherein the first end of
the cable structure is integral with the main body and wherein the
second end of the cable structure has a plurality of locking teeth
and the main body is constructed and arranged to engage certain of
the locking teeth.
17. A frame structure comprising: a composite frame defining a
closed structure, the closed structure having an interior periphery
defining a portion of a continuous channel in the frame, and a
reinforcing structure comprising: a main body secured within the
channel at a certain location, and a cable structure having first
and second ends, the first end being coupled with the main body,
and the cable structure extending from the certain location about
the periphery and within the continuous channel and back generally
to the certain location with the second end being secured to the
main body so that the cable structure provides compression to the
frame.
18. The frame structure of claim 17, wherein the second end of the
cable structure is adjustably coupled with the main body to control
tension of the cable structure.
19. The frame structure of claim 18, wherein the second end of the
cable structure and the main body are constructed and arranged to
be in adjustable treaded engagement.
20. The frame structure of claim 18, wherein the first end of the
cable structure is integral with the main body and wherein the
second end of the cable structure has a plurality of locking teeth
and the main body engages certain of the locking teeth.
21. The frame structure of claim 17, wherein the frame is composed
of vinyl.
22. The frame structure of claim 21, wherein the frame is a window
frame.
23. A method of providing compression to a composite frame, the
frame defining a closed structure having a periphery defining a
portion of a continuous channel in the frame, the method including:
providing a reinforcing structure having a main body and a cable
structure having first and second ends, the first end being coupled
with the main body, securing the main body within the channel at a
certain location, orienting the cable structure to extend from the
certain location about the periphery and within the continuous
channel and back generally to the certain location, and securing
the second end to the main body so that the cable structure
provides compression to the frame.
24. The method of claim 23, wherein the second end of the cable
structure is adjustably coupled with the main body to control
tension of the cable structure, the method including adjustably
securing the second end to the main body to control tension of the
cable structure.
25. The method of claim 23, further including sealing at least
portions of the frame by applying a gel coating to the portions.
Description
[0001] This application is a Continuation-in-Part of U.S. patent
application Ser. No. 10/175,021, filed on Jun. 18, 2002, which is a
continuation of U.S. patent application Ser. No. 09/679,220, filed
on Oct. 3, 2000, now U.S. Pat. No 6,678,934 B1, which in turn is
based on Provisional Patent Application Ser. No. 60/157,625, which
was filed on Oct. 4, 1999, and priority is claimed thereto.
FIELD OF THE INVENTION
[0002] This invention relates to the production of window frame
systems and, more particularly, to structure for reinforcing and
sealing composite window frames.
BACKGROUND OF THE INVENTION
[0003] Window frames made of composite material such as vinyl have
gained popularity due to their lightweight and corrosion
resistance. However the production process is long, tedious and
marred with inconsistencies in quality, physical dimensions and
architectural nature the corners and other joints of conventional
composite windows may not be sufficiently robust due to the
material having low rigidity, becoming brittle and damaged by the
clean up process. Thus, there is a need to provide a reinforcing
structure to strengthen a composite window frame and a mechanism
for sealing the corner from air and water infiltration.
SUMMARY OF INVENTION
[0004] An object of the invention is to fulfill the need referred
to above. In accordance with the principles of the present
invention, this objective is achieved by a method of creating a
better process for producing the window system as well as sealing
and reinforcing a composite frame. The method includes receiving
material for processing, the material having surfaces defining at
least one continuous channel therein; cutting the received material
to a desired length; forming at least one notch in the material by
cutting the material at certain angles thereby defining a pair of
notch surfaces; placing reinforcing structure within at least a
portion of the channel; and folding the material at the notch so
that the notch surfaces are in abutting relation and moving the
ends to be in abutting relating to define a closed frame with the
reinforcing structure, disposed within the channel in the closed
frame, providing sealing properties and reinforcement to the
frame.
[0005] In accordance with another aspect of the invention, a frame
structure includes a composite frame defining a closed structure.
The closed structure has an interior periphery defining a portion
of a continuous channel in the frame. A reinforcing structure
includes a main body secured within the channel at a certain
location, and a cable structure or roll-formed metallurgical
materials having first and second ends. The first end is coupled
with the main body. The cable structure extends from the certain
location about the periphery and within the continuous channel and
back generally to the certain location with the second end being
secured to the main body so that the cable structure provides
compression to the frame.
[0006] Other objects, features, functionality and characteristics
of the present invention, as well as the methods of operation and
the functions of the related elements of the structure, the
combination of parts and economics of manufacture will become more
apparent upon consideration of the following detailed description
and appended claims with reference to the accompanying drawings,
all of which form a part of this specification.
BRIEF DESCRIPTION OF DRAWINGS
[0007] The invention will be better understood from the following
detailed description of the preferred embodiments thereof, taken in
conjunction with the accompanying drawings, wherein like reference
numerals refer to like parts, in which:
[0008] FIG. 1 is a side view of a linear profile being cut, notched
and processed to be used as a window frame in accordance with the
principles of the invention.
[0009] FIG. 2 is a perspective view of the cut, processed and
notched profile of FIG. 1.
[0010] FIG. 3 is a perspective view of the profile of FIG. 2 being
folded at the notches to define a window frame.
[0011] FIG. 4 is a perspective view of the frame of FIG. 3 shows a
pre-assembled, processed and folded frame and prior to glazing.
[0012] FIG. 5 is a front view of an assembled frame of FIG. 4 after
glazing and including a reinforcing and sealing structure in
accordance with an embodiment of the invention.
[0013] FIG. 6 is an enlarged view of the corner portion depicting
the insertion cam with a threaded core used to tighten the frame
and create sealing properties in the corners or joints of the frame
encircled at 6 in FIG. 5.
[0014] FIG. 7 a perspective view of the corners cam system from an
exterior portion of FIG. 6.
[0015] FIGS. 8a-8f are front views of window frame systems of
various shapes, each including the reinforcing and sealing
structure of FIG. 6.
[0016] FIG. 9 is a perspective view of a corner portion of a frame
system showing a reinforcing and sealing structure utilizing a
one-way tension strap interlocking mechanism in accordance with
another embodiment of the invention.
[0017] FIG. 10 is a perspective view of a corner portion of a frame
system showing dual one-way tension strap interlocking mechanisms
used for reinforcing and sealing structures of FIG. 9.
[0018] FIG. 11 is a side view of a linear profile including corner
reinforcing and sealing structure in accordance with still another
embodiment of the invention.
[0019] FIG. 12 is a front view of a window frame formed by folding
the profile of FIG. 11 and shown with the reinforcing and sealing
structure in an operative position.
[0020] FIG. 13 is an enlarged view of a reverse flex cam
interlocking coupling device for reinforcing and sealing structure
of FIG. 12.
[0021] FIG. 14 is a front view of a widow frame system including
corner reinforcing and sealing structures in accordance with yet
another embodiment of the invention.
[0022] FIG. 15 is an enlarged, sectional view of the internal
interlocking system portion encircled at 15 in FIG. 14.
[0023] FIG. 16 is a cut-away view of a widow frame including
individual components that comprise a reinforcing and sealing
structure in accordance with yet another embodiment of the
invention.
[0024] FIG. 17 is a view of a window frame including exterior
gel-coat applied material used as a reinforcing and sealing
structure in accordance with an embodiment of the invention.
[0025] FIG. 18 is a front view of a window frame including multiple
corner tension plug clips used as restrictors from separation and
utilized in combination as a reinforcing structure in accordance
with yet another embodiment of the invention.
[0026] FIG. 19 is a perspective view of a corner portion of a frame
system showing another internal embodiment restricting shear or
tensile degradation to the frame and used as a reinforcing and
sealing structure.
[0027] FIG. 20 is a front view of a window frame including an
internal bladder comprised of a polymer material as a reinforcing
and sealing structure in accordance with yet another embodiment of
the invention.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EXEMPLARY
EMBODIMENTS
[0028] With reference to FIG. 1, a side view of a profile 10, prior
to folding, but after being notched and cut is shown in accordance
with the principles of the present invention. The profile 10 is
employed as a frame of a window system, as will be explained more
fully below. The profile 10 is preferably made of a synthetic
material or composition, including typically vinyl, wood composite,
plastic, metal, resin, fiberglass, PVC, Cellular PVC, ABS,
co-extrusion, pultrusion and/or fiber wound bendable material. As
shown in FIG. 1 each end 12 and 14 is cut by tooling 15 at
generally a 45-degree angle. Notches 18, for defining corners of
the frame, are cut into the profile 10 at certain locations via
tooling 17. The notches 18 are formed by cutting the profile at
certain angles, thereby defining a pair of notch surfaces 11, 13 at
each notch 18. Also, vent, subcomponent assemblies and drain holes
20 are provided in the profile 10 via tooling 19.
[0029] FIG. 2 is a perspective view of a typical new construction
profile 10 after the ends 12 and 14 and notches 18 have been formed
or cut. A nail fin 22 extends from a bottom of the profile 10 but
can be trimmed back at a 90 degree angle. A glazing bead track 24
is provided adjacent to a glass track 26, the other side of which
is formed by a glass tower 28. The glass tower 28 and a vent tower
30 form walls of a vent track 32. Weep/drainage holes 34 are in
communication with the holes 20 to permit water to drain from the
frame.
[0030] With reference to FIG. 3, folding of the profile 10 of FIG.
2 is shown to provide a closed structure. In the embodiment, the
closed structure is a rectangular frame, generally indicated at 36,
in FIG. 4. More particularly, the profile 10 is folded at the
notches 18 causing surfaces 11 and 13 to be in abutting relation to
define corners 38, 40 and 42. Ends 12 and 14 are brought into
abutting relation to define corner 44 (FIG. 4). The process of
manufacturing the frame 36 is described in my earlier U.S. Pat. No.
6,678,934, the content of which is hereby incorporated into the
present specification by reference.
[0031] A completed window frame assembly, generally indicated at
46, is shown in FIG. 5 including the frame 36, upper glazing 48,
lower glazing 50 and meeting rail 52. Reinforcing and sealing
structure, in accordance with an embodiment of the invention, is
shown generally indicated 54 in FIG. 5 and is best shown in FIGS. 6
and 7. The reinforcing structure 54 includes a main body 56 secured
within a continuous channel 58 defined in part by an interior
periphery 61 of the closed frame 36. The reinforcing and sealing
structure 54 also includes a cable structure 60. The cable
structure 60 has a first end 59 fixed to or integral with the body
56 at one corner of the frame 36, for example, corner 44. As shown
in FIG. 5, the cable structure 60 extends from corner 44 within the
channel 58, around corners 38, 40, 40 and back the corner 44 and
thus to the main body 56.
[0032] Hence, with reference to FIG. 6, a second end 62 of the
cable structure 60 is coupled with a movable member 64. In the
embodiment of FIGS. 6 and 7, the movable member 64 is in treaded
engagement with the main body 56 so that tension of the cable
structure 60 can be adjusted. More particularly, access to the
movable member 64 can be obtained through opening 66 in the frame
36 and the movable member 64 can be moved via threaded engagement
in opposite directions to adjust the tension of the cable structure
60. Once the desired tension is set, the opening 66 in the frame
can be sealed. Since the cable structure 60 is disposed about the
entire periphery of the glazings 48 and 50, the cable structure 60
compresses the frame 36, maintaining abutting corner surfaces in
abutting relation to provide a more robust window system 46.
[0033] The reinforcing structure 54 can be employed in windows
system of various shapes. For example, FIGS. 8a-8f show window
frame systems having frames 36a-36f, respectively, of various
shapes with each frame including the reinforcing structure 54.
[0034] With reference to FIG. 9, another embodiment of the
reinforcing and sealing structure is shown generally indicated at
54'. Reinforcing and sealing structure 54' is preferably a
conventional bundle tie or gear track system of the type described
in U.S. Pat. No. 3,887,965, the contents of which is hereby
incorporated into the present specification by reference. Thus, the
reinforcing and structure 54' has a main body 56' integral with a
first end 59' of the cable structure 60'. The main body 56 has an
internal member (not shown) that adjustably engages external teeth
68 of end 62' of the cable structure 60' to set the desired tension
of the cable structure 60'. FIG. 10 shows the use of two
reinforcing and sealing structures 54' in a single frame 36. The
reinforcing and sealing structure 54' can be employed in frames
having the shapes shown in FIGS. 8a-8f.
[0035] The reinforcing and sealing structure 54 or 54' is placed in
the channel 58 when the profile 10 is in the non-folded condition
(FIG. 1). The profile 10 is then folded at the notches 18 with the
ends 12 and 14 placed in abutting relation. Thereafter, the second
end 62 or 62' of the cable structure is adjustably secured to the
main body of the reinforcing structure.
[0036] With reference to FIG. 11, another embodiment of a
reinforcing and sealing structure is shown, generally indicated at
68, in the profile 10 prior to folding thereof. The reinforcing and
sealing structure 68 includes a mechanism 70 placed in each notch
18 in the profile 10, extending into channel 58. As best shown in
FIG. 13, each mechanism 70 includes a pair of elements 72, 74 that
preferably pivot with respect to base 76 from an inoperative
position (dashed lines in FIGS. 11 and 13) to an operative position
(solid lines in FIG. 13 and dashed lines in FIG. 12). Thus, when
each mechanism 70 is placed at each corner formed by the notch 18,
the elements 72, 74 are in an inoperative position, and during the
folding step, the elements 72, 74 pivot about base 76 to the
operative position maintaining the pair of notch surfaces 11, 13 in
abutting relation. The base 76 also adds rigidity to the associated
corner. Each mechanism 70 includes ratchet structure 78 to lock the
elements 72, 74 in the operative position. This mechanism 70
preferably also includes a hollow core 75 that is used as a conduit
to the sealing points of the frame so that a sealing material can
be applied via injection through the mechanism 70 and applied as
needed or desired to the required application point via the conduit
in core 75.
[0037] Instead of providing the ratchet and having each element 72,
74 extend separately into in an associated frame segment as shown
in FIG. 12, the elements 72, 74 can be configured to engage or
interlock at a corner upon folding the profile 10 at the notch when
defining the corner. Corner 44 formed by the abutting ends 12 and
14 of the profile 10 preferably includes a non-pivoting reinforcing
structure 80 for ease of assembly. Reinforcing structure 80 can be
of the type shown in FIG. 15, as will be described below.
[0038] With reference to FIGS. 14 and 15, another embodiment of
reinforcing and sealing structure, generally indicated at 80,
includes a pair of members 82, 84 within channel 58 at each corner.
One member 82 of each pair is disposed transversely with respect to
the other member 84 of the pair. A locking member, preferably in
the form of a pin 86 secures the members 82, 84 together in
abutting relation. An opening 88 is provided in the frame 36 for
inserting the pin 86. The members 82 and 84 can be placed prior to
folding of the profile 10 and then after folding the profile 10 to
define the closed frame 36, the pin 86 can be used to secure the
members 82 and 84 to maintain the corner surfaces in abutting
relation.
[0039] FIG. 16 shows another embodiment of reinforcing and sealing
structure, generally indicated at 90. The reinforcing structure 90
includes a plurality of clips that are fixed about portions of
corners of the vent tower 30, which generally tends to be the weak
point of current thermal applied corner applications. The clips
simply slip over portion of the vent tower to increase structural
integrity of the frame 36.
[0040] FIG. 17 shows a reinforcing and sealing structure in the
form of a plate 92 secured to each exterior corner of the frame 36
to increase sealing performance as well structural integrity of the
frame 36. It can be appreciated that the plate 92 can be provided
at any corner portion (interior or exterior) of the frame 36.
[0041] FIG. 18 shows yet another embodiment of reinforcing and
sealing structure, generally indicated at 94. A reinforcing
structure 94 is provided at each interior corner of the frame 36
and is in the form of a generally L-shaped bracket 96 having
locking tabs 98 extending there-from that are received in
associated recesses 100 provided in the frame 36.
[0042] FIG. 19 shows still another embodiment of reinforcing
structure, generally indicated at 102. A reinforcing structure 102
is provided at each corner of the frame 36 and is in the form of a
generally L-shaped member 104 having a first portion 106 and a
second portion 108. The first portion has serrations 110 for
engaging surfaces defining a channel 112 in the glass tower 28.
Portion 108 is generally smooth for ease of insertion into a
channel of a glass tower of an adjacent section (not shown) of the
profile 10. Portion 106 can be inserted prior to folding of the
profile and portion 108 can be inserted during the folding of the
profile 10 to define the frame.
[0043] It can be appreciated that other methods for providing
structural or sealing integrity to a composite frame can include,
for example, injecting polymer 114 into the corners or entire
hollow portions of the frame 36 (FIG. 20), using a polymer gel
coating application in conjunction with a mechanical reinforcing
structure at the corners of the frame, and hot plate welding of the
abutting corner surfaces prior to assembling the folded profile 10.
The reinforcing and sealing structure increases the structural
integrity of the frame and provides a seal tight exterior as well
as an aesthetically pleasing finished product.
[0044] Although the reinforcing and sealing structure has been
described with a profile 10 that is folded to define a frame 36, it
can be appreciated that the reinforcing structure can be used in a
frame manufactured by other methods such as joining separate
profile segments. In addition, adhesive, clips, and/or fasteners
and the like can be employed to help mount the reinforcing
structure within the frame 36. Furthermore, the various embodiments
of the reinforcing and sealing structure described herein can be
used in combination with each other within a common frame.
[0045] The window frame system can be formed in a wide range of
window shapes and configurations, including but not limited to
squares, rectangles, triangles and other polygons, curved sides,
including rounds, half rounds, circle segments, and other curved
shapes, single hung, double hung, main frame, slider, fixed frame,
vent or sash, patio door, screen door, storm door, casement/awning
and the like.
[0046] The foregoing preferred embodiments have been shown and
described for the purposes of illustrating the structural and
functional principles of the present invention, as well as
illustrating the methods of employing the preferred embodiments and
are subject to change without departing from such principles.
Therefore, this invention includes all modifications encompassed
within the spirit of the following claims.
* * * * *