U.S. patent application number 11/477081 was filed with the patent office on 2006-11-02 for balance system for sash window assembly.
Invention is credited to Vincent F. Eslick, Richard A. Gardner, George E. Heid, Mark V. Murphy, James G. Prete, Steven E. Schultz.
Application Number | 20060242814 11/477081 |
Document ID | / |
Family ID | 22732393 |
Filed Date | 2006-11-02 |
United States Patent
Application |
20060242814 |
Kind Code |
A1 |
Prete; James G. ; et
al. |
November 2, 2006 |
Balance system for sash window assembly
Abstract
A balance assembly (15) is provided for a sash window assembly
(10). The sash window assembly (10) has a sash window (12) slidable
within a master frame (14). The balance assembly (15) has an
elastomer balance member (30) having one end adapted to be
connected to the master frame (14) and another end adapted to be
connected to the sash window (12) to provide an upward biasing
force to the sash window (12). A system (50) is provided for
custom-manufacturing the balance member (30) and for
custom-manufacturing a sash window assembly (10) incorporating the
balance member (30).
Inventors: |
Prete; James G.; (Chicago,
IL) ; Gardner; Richard A.; (Belvidere, IL) ;
Schultz; Steven E.; (Rockford, IL) ; Murphy; Mark
V.; (Oak Park, IL) ; Eslick; Vincent F.;
(Chicago, IL) ; Heid; George E.; (Rockford,
IL) |
Correspondence
Address: |
Paul J. Nykaza;Wallenstein & Wagner, Ltd.
53rd Floor
311 South Wacker Drive
Chicago
IL
60606-6630
US
|
Family ID: |
22732393 |
Appl. No.: |
11/477081 |
Filed: |
June 28, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10840895 |
May 7, 2004 |
7093349 |
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11477081 |
Jun 28, 2006 |
|
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|
10342491 |
Jan 15, 2003 |
6751904 |
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10840895 |
May 7, 2004 |
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|
09838705 |
Apr 19, 2001 |
6523307 |
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10342491 |
Jan 15, 2003 |
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60198198 |
Apr 19, 2000 |
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Current U.S.
Class: |
29/407.1 ;
16/193; 29/445; 29/707; 49/445 |
Current CPC
Class: |
E05D 13/1207 20130101;
Y10T 29/53 20150115; E05D 13/12 20130101; Y10T 16/6298 20150115;
Y10T 16/635 20150115; E05Y 2900/148 20130101; Y10T 29/49861
20150115; Y10T 29/5303 20150115; Y10T 29/534 20150115; E05D 13/10
20130101; E05F 1/16 20130101; Y10T 29/53365 20150115; Y10T 29/4978
20150115; Y10T 29/49829 20150115; E05D 13/1215 20130101; E05D 15/22
20130101 |
Class at
Publication: |
029/407.1 ;
049/445; 016/193; 029/445; 029/707 |
International
Class: |
B23Q 17/00 20060101
B23Q017/00; B23P 21/00 20060101 B23P021/00; B23P 9/00 20060101
B23P009/00; E05D 13/00 20060101 E05D013/00 |
Claims
1. A balance system for a sash window assembly, the sash window
assembly having a sash window slidable within a master frame, the
balance system comprising an elastomer balance member having one
end adapted to be connected to the master frame and another end
adapted to be connected to the sash window to provide an upward
biasing force to the sash window.
2. The balance system of claim 1 wherein the balance member has a
first end having a first loop, the first loop adapted to receive a
fastener to fasten the first end to the master frame.
3. The balance system of claim 2 wherein the balance member has a
second end having a second loop, the second loop adapted to be
attached to a brake shoe connected to the sash window.
4. The balance system of claim 1 wherein the balance member has a
generally cylindrical cross-section.
5. The balance system of claim 1 wherein the balance member
comprises a first elastomer member and a second elastomer member,
the members being coextruded.
6. The balance system of claim 1 wherein the balance member
comprises a plurality of elastomer members woven together.
7. The balance system of claim 1 wherein the balance member
comprises a plurality of elastomer members sequentially attached to
one another.
8. A balance system for a sash window assembly, the sash window
assembly having a sash window slidable within a master frame, the
balance system comprising an elastomer balance member made from
silicone rubber, the member having a generally cylindrical
cross-section and having one end adapted to be connected to the
master frame and another end adapted to be connected to the sash
window to provide an upward biasing force to the sash window.
9. The balance system of claim 8 wherein the balance member has a
first end having a first loop, the first loop adapted to receive a
fastener to fasten the first end to the master frame.
10. The balance system of claim 9 wherein the balance member has a
second end having a second loop, the second loop adapted to be
attached to a brake shoe connected to the sash window.
11. The balance system of claim 8 wherein the balance member
comprises a first elastomer member and a second elastomer member,
the members being coextruded.
12. The balance system of claim 8 wherein the balance member
comprises a plurality of elastomer members woven together.
13. The balance system of claim 8 wherein the balance member
comprises a plurality of elastomer members sequentially attached to
one another.
14. A balance member for a balance system for a sash window
assembly, the sash window assembly having a sash window slidable
within a master frame, the balance member having one end adapted to
be connected to the master frame and another end adapted to be
connected to the sash window to provide an upward biasing force to
the sash window, the balance member comprising a silicone rubber
member.
15. A method for manufacturing a plurality of sash window
assemblies of varying dimensions, each of the sash window
assemblies including a master frame, a sash slidable within the
master frame, and a balance system coupled between the master frame
and the sash, the method comprising: providing the master frames;
assembling one of the sashes within each of the master frames;
providing a length of elastomeric material; determining an amount
of the elastomeric material needed to form the balance system of
each of the sash window assemblies based upon each of the sashes'
particular dimensions; cutting each of the determined amounts of
elastomeric material from the provided length; and installing each
of the cut amounts of elastomeric material between the master frame
and the sash of each of the respective sash window assemblies.
16. The method of claim 15 wherein said determining step is
performed by a computer.
17. The method of claim 15 wherein the step of providing the master
frames includes the step of assembling the master frames.
18. A system for manufacturing a plurality of sash window
assemblies of varying dimensions, each of the sash window
assemblies including a master frame, a sash slidable within the
master frame, and a balance system coupled between the master frame
and the sash, the system comprising: means for providing a length
of elastomeric material; means for determining an amount of the
elastomeric material needed to form the balance system of each of
the sash window assemblies based upon each of the sashes'
particular dimensions; and means for cutting each of the determined
amounts of elastomeric material from the provided length.
19. The system of claim 18 including means for installing each of
the cut amounts of elastomeric material between the master frame
and the sash of each of the respective sash window assemblies.
20. The system of claim 18 wherein the determining means comprises
a computer.
21. The system of claim 18 wherein the providing means comprises a
spool of the elastomeric material.
22. A system for manufacturing a plurality of sash window
assemblies of varying dimensions, each of the sash window
assemblies including a master frame, a sash slidable within the
master frame, and a balance system coupled between the master frame
and the sash, the system comprising: a spool of elastomeric
material; a computer for determining an amount of the elastomeric
material needed to form the balance system of each of the sash
window assemblies based upon each of the sashes' particular
dimensions; and means for cutting each of the determined amounts of
elastomeric material from the spool of elastomeric material.
23. The system of claim 22 including means for assembling the
master frames.
24. The system of claim 23 including means for assembling one of
the sashes within each of the assembled master frames.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of and claims
the benefit of co-pending U.S. Non-Provisional application Ser. No.
10/840,895, filed May 7, 2004, which is a continuation of and which
claims the benefit of U.S. Non-Provisional application Ser. No.
10/342,491, filed Jan. 15, 2003, now U.S. Pat. No. 6,751,904,
issued Jun. 22, 2004, which is a continuation application of and
which claims the benefit of U.S. Non-Provisional application Ser.
No. 09/838,705, filed Apr. 19, 2001, now U.S. Pat. No. 6,523,307,
issued Feb. 25, 2003, which is a continuation-in-part application
and which claims the benefit of U.S. Provisional Application No.
60/198,198, filed Apr. 19, 2000, all of which are expressly
incorporated by reference and made a part hereof.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
TECHNICAL FIELD
[0003] The present invention relates to a balance system for a
sliding member and, more particularly to a balance system that can
be custom manufactured into a variety of sash window assemblies and
that utilizes an elastomer balance member.
BACKGROUND OF THE INVENTION
[0004] A pivotal sash window adapted for installation in a master
frame of a sash window assembly is well-known. The sash window
assembly typically has opposed, vertically extending guide rails to
enable vertical reciprocal sliding movement of the sash window in
the master frame while cooperatively engaged with the guide rails
or shoe channels. The sash window has a top sash rail, a base and a
pair of stiles cooperatively connected together at adjacent
extremities thereof to form a sash frame, usually a rectangular
frame. Typically, a pair of spaced tilt-latches are installed on,
or in, opposite ends of the top sash rail. Retracting a latch bolt
in each tilt-latch simultaneously allows the sash window to be
tilted inwardly. To this end, the sash window is pivotally
supported at its base by a pair of sash balance brake shoes. The
brake shoes slide within the guide rails which are typically in the
form of channels.
[0005] A balance assembly is typically included with the sash
window assembly to counterbalance the sash window within the master
frame. One form of the balance assembly includes a spring that is
connected at one end to a top portion of the master frame,
typically within the shoe channel, and at another end to the brake
shoe. The spring exerts an upwardly biasing force against the
weight of the sash window. Different types of springs have been
used in the balance assemblies. For example, a leaf spring is wound
into a coil which is mounted to the guide rail and a free end of
the spring is connected to the brake shoe. Some balance systems
have been disclosed reversing the leaf spring configuration wherein
the coiled end of the leaf spring is connected to the brake shoe
and the free end is connected to the guide rail. Conventional
spiral coil springs have also been used in balance systems. Block
and tackle balance systems have also been utilized. These balance
systems can be costly and can require large shoe channels to
accommodate the balance systems.
[0006] In certain instances, the weight of the sash window requires
increased counterbalance forces. Thus, multiple leaf springs have
been used in tandem to increase these forces. Because windows can
vary in size and weight, it can be difficult to specify a standard
balance system that provides the most optimum counterbalance force
against each sash window. As a result, window manufacturers must
carry several different models of a balance systems having
different sized springs that offer different counterbalance forces.
This increases required inventories and factory space required to
house all of the balance systems.
[0007] The present invention is provided to solve these and other
problems.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a
balance system to counterbalance a weight of a sash window of a
sash window assembly.
[0009] The master frame has opposed, vertically extending guide
rails in the form of channels. The sash window has a top sash rail,
a base and a pair of stiles cooperatively connected together at
adjacent extremities to form a frame. A balance system is provided
to counterbalance the sash window. The balance system includes a
balance member. A brake shoe can be provided on each side of the
sash window. The brake shoe is connected to the balance member. The
sash window is pivotally supported at its base by the brake
shoes.
[0010] In accordance with one aspect of the invention, a system is
provided to custom manufacture balance systems to be installed in
sash window assemblies. According to another aspect of the
invention, a balance system is provided using multiple balance
members in tandem. The balance members are sized to provide varying
counterbalance forces. In a preferred embodiment, a system is
provided wherein three different balance members are provided. The
balance members are chosen to provide different counterbalance
forces.
[0011] According to another aspect of the invention, the balance
member is an elastomer member. In one preferred embodiment, a
plurality of elastomer members are woven together to form the
balance member connected to the brake shoe.
[0012] According to another aspect of the invention, an elastomer
balance member is provided having one end adapted to be connected
to the master frame and another end adapted to be connected to the
sash window to provide an upward biasing force to the sash window.
In one embodiment, the balance member has a first end having a
first loop. The first loop is adapted to receive a fastener to
fasten the first end to the master frame. The balance member also
has a second end having a second loop. The second loop is adapted
to be attached to a brake shoe connected to the sash window. In one
preferred embodiment, the elastomer member is a silicone rubber
member.
[0013] According to another aspect of the invention, the elastomer
balance member has a generally cylindrical cross-section. According
to yet another aspect of the invention, the balance member
comprises a first elastomer member and a second elastomer member
wherein the members are coextruded. According to a further aspect
of the invention, the balance member comprises a plurality of
elastomer members woven together.
[0014] According to another aspect of the invention, a balance
system is provided having a brake shoe and a balance member. The
brake shoe is adapted to be connected to the sash window. The
balance member has one end adapted to be connected to the master
frame and another end adapted to be connected to the sash window to
provide an upward biasing force to the sash window. The balance
member has a first elastomer member having a first end and a second
end wherein the first end is connected to the brake shoe. A first
joiner is connected to the second end of the first elastomer
member. A support member is provided and is fastened to an upper
portion of the master frame. A cord is provided having an
intermediate portion extending between a first end and a second
end. The first end of the cord is attached to the first joiner and
the intermediate portion passes over the support member. A second
joiner is connected to the second end of the cord. A second
elastomer member has a first end and a second end wherein the first
end is connected to the second joiner and the second end is adapted
to be connected to the master frame.
[0015] According to a further aspect of the invention, a system for
custom-manufacturing a sash window assembly is provided. A master
frame conveyor is provided wherein frame members are conveyed to
different stations and are formed into a master frame. A sash
window conveyor is provided wherein extrusion members and glass
panes are conveyed to different stations and are formed into a sash
window. A balance system conveyor is provided wherein a plurality
of balance members are provided and one or more balance members are
selected according to specifications of the sash window and are
connected to a brake shoe to form a balance system. The balance
system is installed into the master frame. The sash window is
installed into the master frame and is connecting to the balance
system. The selection of the balance member is controlled based on
the specifications of the sash window.
[0016] According to a further aspect of the invention, a balance
system is provided for a closure of an opening in a structure, the
closure slidable within the structure. An elastomer member has one
end adapted to be connected to the structure and another end
adapted to be connected to the closure to provide a biasing force
to the closure. The closure can be vertically or horizontally
operable. The closure can be as sash window, a sliding door or a
garage door.
[0017] According to yet another aspect of the invention, a system
is provided that biases a sliding member slidable within a support
structure. An elastomer member has one end adapted to be connected
to the sliding member and another end adapted to be connected to
the closure to provide a biasing force to the closure. The
elastomer member is placed in tension for an extended period of
time. The sliding member can be, among other things, a sash window
or door.
[0018] Other features and advantages of the invention will be
apparent from the following specification taken in conjunction with
the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] To understand the present invention, it will now be
described by way of example, with reference to the accompanying
drawings in which:
[0020] FIG. 1 is a perspective view of a double-hung sash window
assembly;
[0021] FIG. 2 is a perspective view of a sash window having a
balance assembly of the present invention;
[0022] FIG. 3 is a perspective view of a sash window having another
embodiment of a balance assembly of the present invention;
[0023] FIG. 4 is a perspective view of a sash window having another
embodiment of a balance assembly of the present invention;
[0024] FIG. 5 is a force v. sash travel diagram for different
balance systems of the present invention as well as a conventional
balance system;
[0025] FIG. 6 is a perspective view of a balance system of the
present invention;
[0026] FIG. 7 is a front elevation view of another balance system
of the present invention;
[0027] FIG. 8 is a perspective view of the balance system shown in
FIG. 7;
[0028] FIG. 9 is an enlarged cross-sectional view of a balance
member of the present invention;
[0029] FIG. 10 is a schematic diagram of an automated system for
manufacturing sash windows having balance systems of the present
invention;
[0030] FIG. 11 is a perspective view of a block and tackle balance
assembly incorporating an elastomer balance member;
[0031] FIG. 12 is a schematic view of a balance member comprising a
plurality of balance members sequentially attached;
[0032] FIG. 13 is an elevational view of a sliding door having an
elastomer balance member attached between the door and a door
frame; and
[0033] FIG. 14 is a schematic view of a garage door utilizing an
elastomer balance member.
DETAILED DESCRIPTION
[0034] While this invention is susceptible of embodiment in many
different forms, there is shown in the drawings and will herein be
described in detail preferred embodiments of the invention with the
understanding that the present disclosure is to be considered as an
exemplification of the principles of the invention and is not
intended to limit the broad aspect of the invention to the
embodiments illustrated.
[0035] FIG. 1 shows a balance assembly of the present invention
used in a sash window assembly 10 generally designated with the
reference numeral 10. The sash window assembly 10 shown in FIG. 1
is a double-hung window assembly having a pair of pivotal sash
windows 12 installed in a master frame 14. Tilt-latches 13 are used
with the sash window 12. The sash window 12 is pivotally mounted to
the master frame 14 by a balance assembly 15 that also provides an
upward biasing force against the weight of the sash window 12. It
is understood that the balance assembly can also be used with
windows that are not designed to pivot. The balance assembly 15 is
positioned within a shoe channel 19 of the master frame 14. As is
well known, the master frame 14 has opposed, vertically extending
guide rails 16. The guide rails often incorporate shoe channels
that slidingly receive brake shoes as described below. The sash
window 12 has a hollow top sash rail 20, a base 22 and a pair of
hollow stiles 24,26, cooperatively connected together at adjacent
extremities thereof to form a sash frame, typically rectangular
although other shapes are possible. The sash frame could be made
from extrusions or pulitrusions that are filled with fiberglass,
epoxy, plastic, or wood chips. The sash frame could also be solid
and made from wood, masonite or pressboard.
[0036] The balance assembly 15 having a unique balance member will
first be described. A system for custom-manufacturing the balance
assemblies and custom-manufacturing the sash window assemblies
incorporating balance assemblies will then be described.
[0037] As shown in FIG. 1, the balance assembly 15 generally
includes a balance member 30 and a brake shoe 32. The brake shoe 32
is connected to one end of the balance member 30 while another end
of the balance member 30 is connected to the window frame 14. Brake
shoe 32 also receives a sash pin 17 from the sash window 12 thus
connecting the sash window 12 to the brake shoe 32. Thus, the
balance member 30 exerts an upward biasing force to counterbalance
the weight of the sash window 12. The brake shoe 32 has a brake pad
that is adapted to engage the shoe channel 16 in the window frame
14 when the sash window 12 is tilted. It is understood that a
balance assembly 15 is typically connected on opposing sides of the
sash window 12. It is further understood that balance assemblies
are attached to both the lower sash and the upper sash in a
double-hung window assembly.
[0038] While conventional balance members take the form of metal
springs such as coil and spiral springs, the balance member 30 of
the present invention is an elastomer. The elastomeric material
used can be selected from a group including rubber (SBR, EPDM, NBR,
NR, etc.), urethane, acrylic or other polymeric material. The
material can also be a cross-linked thermoplastic or thermoset. In
one preferred form, the balance member 30 is an elastomer member in
the form of a cord that is cylindrical in shape. The cylindrical
shape helps to reduce the chances of the member 30 tearing. The
balance member 30 could also have a rectangular cross-section. The
balance member 30, however, can also take other forms.
[0039] The balance member 30 can comprise a plurality of different
elastomer members that can be spliced together to provide several
different counterbalance forces. This will be described in greater
detail below. The balance members 30 can be formed in several
different thicknesses and widths. Thus, multiple types or
formulations of elastomers can be employed to counter balance a
wide range of sash weights.
[0040] As shown in FIG. 2, the balance member 30 has one end
connected to the window frame or master frame 14. This end can
connect at the head or in the side jamb of the window frame 14. Its
other free end is adapted to connect to the sash window 12,
typically via the brake shoe 32 (not shown). The length of the
balance member 30 is determined by the desired counterbalance force
as well as the size of the window assembly 10. As shown in FIG. 3,
a pulley 34 can be provided in the balance system wherein the
balance member 30 is wound over the pulley 34. In this
configuration, the balance member 30 has its one end connected to a
sill plate 36 of the window frame 14. By using the pulley 34, the
force gradient of the balance member 30 is decreased. As shown in
FIG. 5, a conventional coil spring has constant counterbalance
force such as represented by the dead weight system. A single
balance member 30 has an increased counterbalanced force as sash
travel increases. Using the pulley 34 decreases the force gradient
where there is less of an increase in counterbalance force with
sash travel. Similarly, as shown in FIG. 4, an upper pulley 38 and
a lower pulley 40 can be used. In this configuration, the balance
member 30 is connected to the head jamb 42 of the window frame 14.
As further shown in FIG. 5, this further lessens the force gradient
associated with the balance member 30.
[0041] FIG. 6 further discloses the balance system 30 of the
present invention generally having the balance member 30. In this
embodiment, the balance member can be connected to the brake shoe
32 although it is understood that the brake shoe 32 is not
required. It is understood that the balance system 30 shown in FIG.
6 is positioned in the shoe channel 19 of the master frame 14 as
shown in FIG. 1. The balance member 30 has a first end 100 and a
second end 102. The first end 100 is adapted to be connected to the
master frame 14, and the second end 102 is adapted to be connected
to the sash window 12. The first end 100 has a first loop 104, and
the second end 102 has a second loop 106. The loops 104,106 are
formed by bending distal ends 107 of the member 30 and fastening
the distal ends 107 to the member 30 by a band 108. Other
connecting structure could also be formed by the balance member 30.
In one preferred embodiment, the balance member 30 has a generally
cylindrical cross-section. It is understood, however, that the
balance member 30 can take many different forms.
[0042] The first loop 104 receives a fastener 110 that is adapted
to be fastened to the shoe channel 19 thereby connecting the first
end 100 of the balance member 30 to the master frame 14. The
fastener 110 can take many different forms. The fastener 110 could
be designed to be snap-fit into the master frame 14. The fastener
110 could also be a simple screw or clamp. A ball could also be
connected to an end of the balance member 30 and would be adapted
to fit within a slot/opening in the master frame to connect the
member 30 thereto. The fastener 110 could also include gluing. The
fastener 110 is designed to not damage the integrity of the outer
surface of the balance member 30. The second loop 106 is designed
to be fastened to the brake shoe 32. For example, the brake shoe 32
can be equipped with a post 112 wherein the second loop 106 is
positioned around the post 112. Other attachment means known in the
art are also possible. When installed, the balance member 30 is in
a tensioned state to provide a counterbalance force to the sash
window 12. Thus, the balance member 30 has an initial length L1.
When installed, the balance member 30 is stretched to an elongated
length L2 wherein portions of the balance member 30 move to the
elongated length L2.
[0043] As discussed, the balance member 30 can have different
properties to vary the counterbalance force provided. For example,
different elastomer materials can be used. The balance member 30
can also be made in various lengths and thicknesses. In setting the
length of the elastomer balance member 30, the tensile set of the
material being used is taken into consideration. The tensile set is
the amount of increase (%) in length in a given time after
releasing a tensioned member. The balance member 30 can also
comprise a plurality of elastomer members woven together in braided
form. As shown in FIG. 9, the balance member 30 can be a coextruded
member having an inner material 114 and an outer material 116. The
inner material 114 can be selected from materials that have good
tensile properties. The outer material 116 can be selected from
materials having good atmospheric properties, such as adequate
resistance to weather conditions.
[0044] The balance member 30 is made from an elastomer. In one
preferred embodiment, the elastomer balance member 30 is made from
silicone rubber. The elastomer member 30 is designed to be
maintained in tension for a prolonged period of time and still
provide the required counterbalance force to the sash window 12.
For example, the elastomer balance member 30 is designed for a life
of fifteen to twenty years. The balance member 30 can be made from
different elastomer materials to provide adequate force for varying
prolonged periods of time. It is further understood that the
elastomer balance member 30 provides counterbalance force both in a
static state when the sash window 12 is stationary and in a dynamic
state when the sash window 12 is raised or lowered. Typically, the
elastomer balance member 30 is in a constant, static state of
tension. The elastomer material is subject to general atmospheric
conditions. The material is designed to provide a consistent
counterbalance force notwithstanding warm or cold temperatures, or
moisture.
[0045] FIGS. 7 and 8 disclose another embodiment of a balance
member of the present invention, generally referred to with the
reference numeral 120. The balance member 120 comprises a first
elastomer member 122, a second elastomer member 124, and a cord
assembly 142.
[0046] The first elastomer member 122 has a first end 126 and a
second end 128. The first elastomer member 122 comprises a primary
member 130 and a secondary member 132 that is wrapped around the
primary member 130. The second elastomer member 124 has a first end
134 and a second end 136. Similar to the first elastomer member
122, the second elastomer member 124 comprises a primary member 138
and a secondary member 140 that is wrapped around the primary
member 138. The primary members 130,138 and secondary members
132,140 provide different balance forces and are combined to
fine-tune the overall counterbalance force provided. It is
understood that additional primary or secondary members could also
be used.
[0047] The cord assembly 142 connects the first elastomer member
122 to the second elastomer member 124. It is understood, however,
that the first elastomer member 122 can be directly attached to the
second elastomer member 124. It is further understood that an
elastomer member can be comprised of a plurality of elastomer
members sequentially attached. FIG. 12 schematically shows two
elastomer members 160,162 sequentially attached at respective ends
of the members 160,162. The cord assembly 142 generally includes a
cord 144 and a first joiner 146 and a second joiner 148. The cord
144 has an intermediate portion 150 extending between a first end
152 and a second end 154. The first end 152 is connected to the
first joiner 146 and the second end 154 is connected to the second
joiner 148. The intermediate portion 150 passes over a support
member 156. The support member 156 has a post 158 (FIG. 8) to
support the intermediate portion 150. In an alternative embodiment,
the support member 156 can have a pulley that the intermediate
portion 150 passes around. The first joiner 146 is connected to the
second end 128 of the first elastomer member 122. The second joiner
148 is connected to the first end 134 of the second elastomer
member 124.
[0048] The first end 126 of the first elastomer member 122 is
connected to the brake shoe 32. As shown in FIG. 1, the brake shoe
32 is connected to the sash window 12 by the sash pin 17. The
second end 136 of the second elastomer member 124 is adapted to be
connected to a lower portion of the master frame 14. In a preferred
embodiment, a connector 160 is provided that is adapted to be
connected to the master frame 14. The connector 160 is connected to
the second end 136 of the second elastomer member 124.
[0049] The balance member 30 is positioned within the shoe channel
19. The support member 156 is attached at an upper portion of the
master frame 14. The first elastomer member 122 extends upward from
the brake shoe 32 wherein the cord 144 passes around the support
member 156. The second elastomer member 124 extends downward
wherein the connector 160 is connected to a lower portion of the
master frame 14. The elastomer members 122,124 and cord 144 are
sized to provide the adequate counterbalance force to the sash
window 12. When the sash window 12 is raised or lowered, the cord
144 passes around the support member 156. When the sash window 12
is in its normally closed position, the second joiner 148 will abut
the support member 156 to prevent too much tension from being
applied to the second elastomer member 124.
[0050] The first elastomer member 122 and the second elastomer
member 124 are made from members providing different tensile
forces. This can be accomplished by varying different properties of
the members 122,124. One particular way to vary the force is vary
the diameter of the elastomer members. For example, the first
elastomer member 122 generally has a larger diameter than the
second elastomer member 124 to provide a greater counterbalancing
force. This allows appropriate stretching of each member and takes
into account the tensile set of the members so that the members
will fit within the shoe channel 19 at the appropriate tension. In
addition, by using two elastomer members, added stroke length is
achieved. Upon movement of the window sash 12 to placed the balance
member in a stretched state, the second elastomer member 124 is
weaker than the first elastomer member 122 and, therefore,
stretches first without the first elastomer member 122 stretching.
Upon further movement of the sash window 12, the first elastomer
member 122 and the second elastomer member 124 both stretch. The
members 122,124 are sized such that overtensioning does not occur.
The second joiner 148 abutting the support member 156 will help
assure the second elastomer member 124 is not overtensioned.
[0051] The elastomer member 30 can be incorporated into other
balance systems. For example, as shown in FIG. 11, an elastomer
member 140 can replace the traditional spiral spring of a block and
tackle balance system 142. The elastomer member 140 can be sized or
made from different elastomer materials to fine tune the block and
tackle balancer.
[0052] It is further understood that the balance member 30 can be
utilized in many different applications in addition to a sash
window assembly. The balance member 30 can be used with various
sliding members that can benefit from a biasing force. The balance
member 30 can be used in a structure having an opening wherein a
closure is provided in the opening. The closure can be vertically
operable or horizontally operable. For example, as shown in FIG.
13, an elastomer balance member 178 can be used in a sliding window
application or a sliding door application. A patio door 180 is
slidable within a door frame 182. The balance member 30 has one end
suitably connected to the door 180 and another end suitably
connected to the door frame 182. The balance member 178 can be
connected at various positions such as the bottom of the door 180
although it is preferable to connect the balance member 178 at the
top of the door 180. The balance member 178 provides a biasing
force to assist in opening of the door 180. In another example, a
garage has an opening that is closed by a garage door. FIG. 14
shows a schematic view of a garage door 190 movable in a pair of
tracks 192,194. An elastomer balance member 196 can be attached
between the garage structure (including tracks 192,194) and the
garage door closure 190. Two balance members 196 could also be
used. The balance member could also be used in automotive
applications such as for trunk closures. The balance member can be
utilized in a wide variety of other applications wherein a closure
or other type of member positioned within a support structure
requires a counterbalancing force. The balance member 30 can also
be utilized in a sliding drawer requiring a biasing force such as
for biasing the drawer closed. The balance member 30 could also be
used in aerospace applications where weight and space are a
consideration. The balance member is utilized in tension in both
static and dynamic applications.
[0053] The elastomer balance member 30 of the present invention can
be used as a tension spring and replace conventional metal tension
springs. The elastomer member 30 can be used in applications
wherein the member 30 must be significantly extended for an
extended period of time while maintaining its ability to retract to
its original length. Significant extension can be considered
extension of at least a minimum of 10% of the ultimate elongation.
Ultimate elongation is considered the maximum distance the member
can be stretched before failure. In one particular application,
significant extension can be considered, for example, 10% to 90% of
the ultimate elongation. An extended period of time can be
considered approximately several weeks time. In one particular
application, an extended period of time can be, for example, three
months. In determining whether the member has the ability to
retract to its original length, a time period is set such as five
minutes from being released from tension. Once the member
retraction rate is negligible, the length of the member is
determined. If the member has retracted to approximately within
10-20% of its original length, the member is considered to
adequately maintain its elastomer properties. The elastomer balance
member 30 has such properties. The member 30, such as silicone
rubber in one preferred embodiment, can be significantly extended
for an extended period of time while maintaining its ability to
retract substantially to its original length thus maintaining its
spring properties. It also resists attack from weather conditions
including attacks from atmospheric ozone. It is noted that other
rubbers such as latex rubbers do not have this ability to resist
attack from atmospheric ozone.
[0054] The balance system of the present invention provides many
advantages. Using an elastomer member provides a balance system
requiring a less complex construction. The elastomer system is less
expensive than traditional balance systems utilizing primarily
metal components. The elastomer balance member can be sized to
smaller diameters than, for example, spiral balances thus saving
space. This allows for smaller channels in the master frame. The
elastomer balance member can be fine-tuned to provide a most
optimum counterbalancing force.
[0055] As discussed, the present invention provides a system 50 for
custom-manufacturing of the balance assembly 15 and balance member
30 based on the specific type of sash window assembly 10 being
manufactured. Ideally, all steps of the process are performed at
the window manufacturer site. At the manufacturing site, window
assemblies are sequentially made having various weights and
dimensions. Thus, sequential window assemblies moving along an
assembly line, if having different dimensions, weight etc., will
require different balance assemblies. FIG. 10 shows a schematic
view of the manufacturing system for the sash window assembly 10 in
which all steps are performed at the window manufacturer's site.
The system 50 generally includes a window frame assembly line 52, a
sash window assembly line 54 and a balance assembly line 56. A
computer control 58 is provided that is software controlled to
control the manufacture of the sash window assembly. The computer
control 58 is programmed at the beginning of the manufacturing
process.
[0056] In the sash window assembly line, the individual components
such as glass panes 60 and extrusion members 62 are connected to
form the sash window 12a. Hardware components 64 are also connected
to the sash window 12a. Simultaneously, the window frame assembly
line 52 provides the required frame members 66 to be connected
together to assemble the master frames 14. Any necessary hardware
68 is also connected to the window frame 14a.
[0057] Based on the specifications of the sash window 12a and the
window frame 14a, the computer control 58 specifies to the balance
assembly line 56 which materials are to be used for the balance
member 30. The balance assembly line 56 includes a plurality of
unwind stands 70, or spools, that each support a roll of different
elastomer members. In one preferred embodiment, three different
balance members 30 are provided. The balance members 30a,30b,30c
are rated differently and thus provide different counterbalancing
forces. The balance member 30 is unwound from the stand 70 with a
minimum tension so as not to elongate the material. Depending on
the desired counterbalance force and length, the balance members
30a,30b,30c pass over a cutting/splicing station 72 so that
multiple members 30 can be cut and spliced together. It is
understood that a window assembly 10 may only require a single
balance member 30. In such case, a length of the elastomer material
is unwound and is cut after determining the amount needed based
upon the sash window 12a specifications. The cut and/or spliced
balance members 30 may be wound onto a core and then a brake shoe
32 can be attached thus forming the balance assembly 15.
Alternatively, the members 30 may not be wound onto a core. It is
understood that based on the specifications of the sash window 12a,
a single balance member 30 may be selected or multiple balance
members 30 may be selected.
[0058] The assembly lines are structured wherein the balance
assembly 15a is conveyed to the window frame assembly line 52 and
connected to the window frame 14a. Likewise, the sash window 12a is
conveyed to the window frame assembly line 52 and installed into
the window frame 14a and connected to the balance assembly 15. The
completed sash window assembly 10 is then ready to be shipped. As
discussed, the computer control 58 controls how all of the
individual components come together. The details of the balance
assembly 15 can be calculated by the computer control 58 and
preloaded into the system. Alternatively, the computer control 58
can be provided with tables that will specify the balance assembly
components based on the specifications of the window assembly. The
computer determines the amount of elastomeric material needed to
form the balance member for each sash window assembly. Other
information will also be input into the computer control 58 such as
sash window travel length and sash window weight. This could also
be calculated by using the frame and sash window dimensions and
glass selection.
[0059] With the present system, sash window assemblies can be
manufactured on site utilizing different rated balance systems
based on end-customer demand. With the use of an elastomer as the
balance member 30, cost-savings are utilized as it is less
expensive than conventional metal balance springs. Also, the
balance assemblies are custom-manufactured for each specific sash
window assembly at the time the window assembly is being
manufactured. All this is done right at the window manufacturer
site. Thus, the need for large, multiple SKU balance assembly
inventories is eliminated. Furthermore, because each balance
assembly is manufactured for each specific window assembly, a more
precisely balanced sash window is achieved.
[0060] While the specific embodiments have been illustrated and
described, numerous modifications come to mind without
significantly departing from the spirit of the invention and the
scope of protection is only limited by the scope of the
accompanying Claims.
* * * * *