Patent Application
20080115321
The present invention relates to an adjustable casement window sash, and in particular to a track and hinge assembly, that compensates sash sag, by an adjustment screw.
Generally, casement window sashes are mounted to the window frame by hinges. These hinges may be attached either to the bottom of the window sash, or to the top of the window sash. Conversely, the hinges may be attached to both. It is typical for such a hinge to have a track mountable to the window frame. The sash arm is generally pivotally connected to a mounting shoe block, which is supported and guided, for movement lengthwise across the track. Window hinges of this type are shown, for example, in Tacheny et al. U.S. Pat. No. 4,726,093, and Sandberg et al. U.S. Pat. No. 32,846. In normal operation when the user wishes to open a casement window, let's say, for ventilation purposes or cleaning, the user will turn a crank handle in a clockwise motion, for opening the casement window, and in a counterclockwise motion, for closing the casement window. After repeated opening and closing of a casement window, the window may eventually move out of a squared position, which in turn may prevent the window sash from fully closing, thus preventing the keeper, in the casement window frame, from engaging the latch; this can be burdensome to the user. So then, why do crank-out windows become hard to close after a few years? The answer is what is known in the window industry as “sash sag”. Sash sag has been stated as “the single most asked question concerning the operating casement window today”, but as research has shown there is no simple, clear cut solution to the problem. For purposes of definition, we define the problem of sash sag as the movement of the sash relative to the window frame. The first step toward gaining an understanding of sash sag is to identify the causes. One possible cause of sash sag is something that is referred to as “sash drag”, whereby the sash will drag across the frame or sill as the window is opening or closing. Usually this problem is due to the bottom corner of the latch side of the sash dragging against the frame.
There are many reasons why the sash of a casement window may begin to drag against the window frame: the sash may sag out-of-square because of improper hinge positioning, improper glazing, and poor track attachment by the manufacture, or the frame may settle out of square because of poor installation.
Glazing compounds used by the manufacturers have been observed to take a considerable period of time to set up. During this time it is possible and likely for the sash to sag around the glass thereby possibly moving the sash out of square. Another cause of sash sag attributed to the manufacture is hinge positioning. This is the relationship of the top hinge to the bottom hinge and the side jamb; hinge positioning is critical in window manufacturing. Because of certain manufacturing tolerances in each hinge, there can be as much as 0.019″ lateral movement of the arm assembly within the track, which will accelerate the effects of sash sag in most residential casement windows. Yet another manufacturing defect that will further accelerate sash sag is the improper fastening of the track screws. If the track screws are not driven down as straight as possible, then the track will twist over time, and cause the sash to sag. In addition, there are some types of hinges that have track protrusions which are designed to sink into soft frame materials such as wood. However, sometimes these track protrusions do not fully sink in when the screws are tightened. This condition may allow the track to shift or rotate and contribute to the sash sag. There are some tracks that have a special flat bottom hinge track, as in the present invention, specifically designed for mounting on hard frame materials.
Improper installation of the casement window is the second leading cause of sash sag, regardless of whether a frame leaves the manufacturer without any defects, and is in a square configuration or not, it must be placed into the roughed out opening and secured as squarely as possible. Any deviation from a square frame can result in apparent sash sag. In addition, casement windows which are square (shape) or wider than they are tall compound sash sag problems due to added cantilevered weight. Some experts recommend that when designing and/or specifying a casement window, the sash width should be limited to 66% of the sash height. Once again, any length discrepancies in sash or frame parts will result in the sash or frame being out of square.
Sash sag is a potential problem that requires close control at all levels of the window industry. This control must be exhibited with those who manufacture component parts as well as those who assemble, transport and ultimately install window units. Each item listed above helps add to the compounding of the sash sag problem and it is possible for one or any combination of the above problems to exist!
The earlier methods of correcting the problem of sash sag usually required that the hinge track be provided with slotted holes and that the hinge mounting screws in the slotted holes were to be removed to allow for shifting of the track. Repeated removal of such screws can, however, over the life of a window result in gradual loosening and depleted integrity of the window. In more recent times, sash sag has been corrected with the use of an adjustable hinge. One such type of adjustable hinge that has been employed is that of U.S. Pat. No. 5,152,102 and U.S. Pat. No. 5,074,075, issued to LaSee. In that prior art the inventor implemented an octagonal cam mechanism, so as to allow for sash sag compensation. More recently, U.S. Pat. No. 5,307,539, issued to Bauman, utilized an eccentric shaped adjustable stud, having a flange with surfaces for engaging an adjustment tool, having a pivot portion, about which the swivel arm pivots, and an eccentric neck, frictionally secured to the window frame or the track, about which the pivot axis rotates when the alignment is adjusted. However, this prior art required the user to engage a wrench, the adjustment tool, roughly perpendicular to the hinge axis. Because of the tight spaces associated with casement window hardware, this type of adjustment method can be unduly burdensome to the user. This stud type adjustment was improved upon in U.S. Pat. No. 5,964,011, assigned to Newell, by having the tool access position, in which the tool is engageable with the engagement stud, roughly parallel to the pivot axis. However, this type of configuration is unnecessarily complex with a multitude of different members, which may amount to possible malfunctions of the different members, and an added cost to production. In the present invention, the hinge may be adjusted simply, with the twist of screwdriver, or the simple twist of a finger. This is because of the simplified adjustment post, which consists mainly of a threaded screw and a threaded aperture.
It is an object of the invention to provide a casement hinge which may be easily and precisely installed.
It is another object of the invention to provide a casement hinge which will remain securely mounted and thereby minimize any loosening of the hinge over the life of the window.
It is still another object of the invention to provide a casement hinge which may be easily adjusted over the life of the window to ensure that a tight seal be provided when the window is closed and that the window be easily and smoothly operated at all times.
It is still a further object of this invention to provide a conventional casement sash unit with a screw mechanism, which is adjustable for correcting sash sag during and after installation of the casement window.
The present invention is deigned to compensate for sash sag in casement windows. The typical casement window has a window sash hinged to the window frame. The hinge is generally pivotally connected to a shoe block. This pivotal connection allows the window operator the ability to open and close the window sash. As in most casement windows, after repeated use the window sash may begin to sag, “sash sag”. Conversely, a manufacturing defect, such as those listed above, may also cause the sash to sag. In order to correct the quandary of sash sag, previous casement windows required the relocation of the hinge tracks. However, this caused premature wear of the pivot mount and the pivot mounting hardware, thereby reducing the useable life of the casement window.
The present invention relates to an adjustable pivotally linked hinge and track system for casement windows. The hinge has a sash arm pivotally connected, via a rivet, to a shoe block, which allows for movement across the horizontal plane of a window track. The sash arm is also pivotally connected to a support arm, via another rivet. The support arm has a bored cavity used to house the adjustment mechanism. Moreover, the support arm has a slidable flexible clip that traverses across the top surface of the support arm. In addition, if needed, the support arm has a slit or groove that gives the user additional leverage when disengaging the flexible clip.
The present invention also relates to an adjustment mechanism, which includes a threaded adjustment screw having a first end constructed to receive the tip of a Philips head screwdriver, and a threaded support post capable of receiving the threaded adjustment screw. A circumferential groove is located near the top end of the threaded support post, which is capable of engaging the two opposing flexible arms of the retaining clip.
The present invention further relates to a track assembly that is mounted to a window frame. A track assembly having at least one generally circular aperture for receiving the support post of the adjustment mechanism. A track assembly having a perpendicular rear end portion that has an upper arcuate lip portion.
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
Referring now to the drawings, and, more specifically, to
Support arm 22 may be of generally the same shape as sash arm 11, as seen in
Retaining clip 35 may be constructed of any suitable material known in the art but not limited to metal or metal alloy, wood, polyvinyl chloride (pvc), etc. In the present embodiment the preferred material was a resilient type of metal, so as to allow for engaging support post 90. Retaining clip 35 is slidably interconnected with support arm 22. Retaining clip 35 has roughly “C” shaped edges 36 that hold retaining clip 35 to support arm 22 while allowing retaining clip 35 to traverse along support arm 22 when retaining clip 35 is disengaged from support post 90. In addition, retaining clip 35 has a pair of flexible opposed arms, 38 and 39 that, when pressed against support post 90, engage groove 92, by means of a friction or pressed fit.
Track 70 may be constructed of any suitable material known in the art, but not limited to metal or metal alloy, ceramic, polyvinyl chloride (pvc), etc. In the present embodiment the preferred material for the construction of track 70 was metal. Track 70 may be composed of a generally horizontal elongated track portion 71, having a plurality of longitudinally spaced apertures 72 therein, through which project fasteners for mounting horizontal track portion 71 to window opening, any suitable type of fastener known in the art but not limited to a screw, nail, tack may be used. In the present embodiment the preferred fastener was wood screws. Horizontal track portion 71 may be generally rectangular in shape, as in the present embodiment, but any suitable shape known in the art may be used. In addition horizontal portion 71 has top and bottom surfaces, 76 and 77 respectively. In one embodiment track 70 also may have a vertical portion 73, which may be perpendicular to horizontal elongated track portion 71, so as to form a right angle with horizontal track portion 71. Vertical portion 73 may have an arcuate lip 74 which may be integrally formed therewith and may traverse longitudinally from one end of track 70 to a point located passed the mid-portion of track 70. Arcuate lip 74 acts as a guide for shoe block 13, and thus allows shoe block 13 to slide across horizontal portion 71 in a uniform fashion, and retain shoe block 13 thereto.
In yet another embodiment horizontal track 70 may not have a vertical portion, but rather horizontal track portion 71, may have a rib located on top surface 76 of horizontal track portion 71, and a parallel groove on the base of shoe block 13. In that embodiment shoe block 13 would traverse along the rib of horizontal surface 76.
Shoe block 13 may be of any suitable shape known in the art but not limited to a square, rectangle, and triangle. In the present embodiment the preferred shape for shoe block 13 was a generally rectangular shape with rounded outside corners 78. In addition, shoe block 13 may be constructed from any suitable material known in the art but not limited to metal or metal alloy, plastic, glass filled nylon or any equivalent. In the present embodiment the preferred material for construction of shoe block 13 was plastic. Shoe block 13 has a keeper arm 75 that traverses longitudinally across back edge 76 of shoe block 13. Shoe block 13 may be constructed with a plurality of apertures. In the present embodiment shoe 13 has two circular apertures 80 located near outside corners 78. As mentioned previously shoe block 13 is pivotally connected to sash arm 11 by of rivet 14. Rivet 14 is staked through one of apertures 80, depending on the desired amount of window opening, and is compressed, using a suitable tool or machine, until bottom portion 81 of rivet 14 is larger then diameter of aperture 80. This type of connection will allow for sash arm 11 to pivot during normal operation. Shoe block 13 may be reinforced with additional material so as to add for added strength and longer use. In the present embodiment shoe block 13 has two pieces of reinforcing metal located inside of shoe block 13, underneath apertures 80.
As mentioned previously support post 90 and threaded adjustment screw 29, are located on top surface 76 of horizontal track portion 70, fixed at a position that will allow for optimum performance of hinge. Support post 90 may be a generally cylindrically shaped rivet, but any suitable shape known in the art may be used. In one embodiment support post 90 may have a generally concave bored portion on outside surface. Support post 90 may be composed of any suitable material known in the art, but not limited to metal or metal alloys, ceramic, pvc, etc. In the present embodiment the preferred material for the construction of support post 90 was brass. Support post 90 may be connected to horizontal surface 70 in the same manner as rivet 14. Support post 90 may have a circumferential groove 92 located on the outside top surface 91, for engaging flexible arms 38 and 39. In addition an aperture 93 may be located near the center of support post 90, for receiving threaded adjustment screw 94; aperture 93 may be threaded, or smooth, depending on the screw type. Threaded screw 94 may be of any suitable shape type known in the art, in the present embodiment a threaded screw 94, with crossed slots capable of accepting a Philips head screwdriver, was preferred. One could also have used a variety of other suitable types of screws known in the art, but not limited to a single slot type screw to accept a flat head screwdriver, or a hexagonal aperture to accept an Allen wrench, etc. Furthermore, one may use a knurled or square head style screw rather then a screw that requires a tool for rotation. With that embodiment, in normal operation, one could use the surface of ones finger to adjust the screw. Screw 94 of the present invention may be situated inside of bored cavity 28 so that the area of screw 94 that accepts the tool, or in the case of a knurled screw, the finger, is placed adjacent to front wall 32 of bored cavity 28.
The functionality of the hinge of the present invention is as follows. As mentioned above, sometimes casement windows will begin to sag, “sash sag”. This sag may occur before or after installation. Conversely, sash sag may occur after repeated use of the window 10, i.e. opening and closing. In order to compensate for the sag the user will open window 10 so as to allow sash 12 to be fully extended outward. The user will then apply a force to retaining clip 35, which will disengage retaining clip 35 from circumferential groove 92. This will allow the user the capability of raising support arm 15 over adjustment mechanism 29, and thus, allow access to adjustment mechanism 29. Once the user has access to screw 94, the user can easily turn screw 94 to compensate for the unwanted sash sag. After the adjustment has been made, the user will then return support arm 15 back over adjustment mechanism 29, and press retaining clip 35 back around circumferential groove 92.
In the view above it will be seen that several objects of the invention are achieved and other advantageous results attained.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense.
