The present invention relates generally to methods, apparatus, and a kit for installing window film structures. More particularly, it relates to methods, apparatus, and a kit for easily and reliably installing window film structures in a manner for avoiding formation of permanent film flaws therein diminishing their optical properties, while at the same time may enhance thermal insulation for associated window assemblies.
Window films are generally transparent plastic and/or metallized laminates applied as a thin layer to transparent panels, such as glass windows. Window films are available in many different compositions for bringing about varying effects on the optical and mechanical properties of the underlying transparent panels. Window films can reduce energy costs by minimizing the amount of heat entering a building through sunlight, thereby decreasing the amount of energy needed to cool the building. Window films also act as a filter for reflecting most ultraviolet and infrared wavelengths while allowing passage of visible light. This can result in substantial reductions in cooling costs. As noted, such films reduce the amount of ultraviolet entering a window, and are also often applied to reduce fading of the contents of a room. Other kinds of thin window films include security films applied to prevent glass from shattering, as well as privacy films for controlling the visible light transmitted for effecting privacy purposes.
It will he appreciated that several factors are considered in selecting the correct film to be installed. Such factors include visible light transmission, properties of solar energy to be reflected, and aesthetic considerations, such as distortion free viewing following installation.
Because window films are usually installed by applying them to either or both surfaces of flat finished glass, the resulting laminates are less costly than buying chemically altered specialty glass for bringing about the same desired solutions. Because window films provide energy savings and help protect furnishings among other advantages, they are generally considered to be an investment that pays for itself. As such, they have gained widespread commercial acceptance.
Unless the window films are properly applied to windows, there is a chance that they will crease and fold, during cutting and installation due to their inherent highly flexible nature. Due to the inherent mechanical and chemical properties of these films, their installation can be tedious and subject to several shortcomings particularly in a do-it-yourself context. Generally window films are thin and may be difficult to handle, especially if large window panels are to be laminated. For example, window films are relatively thin, such as up to 4 mils. These thin films have a tendency to fold upon themselves. Measuring and cutting thin films to the correct size before they are directly applied is particularly difficult, especially if irregular window shapes are involved and installation is performed by non-professionals, such as a do-it-yourself installer. Additionally, most window films are covered by a release sheet that must be removed before application of the film on the window. However, there is a strong tendency for the thin adhesive covered film surface to permanently wrinkle, crumple, or crease as the release sheet is manually removed. Accordingly, these film surfaces may stick to themselves even before the release sheet is completely removed. Creasing, wrinkling, etc. may cause permanent film flaws eventually that lead to discarding the films. Moreover, there is a chance that they will cause permanent flaws in the film which diminish their optical properties. Some of these window films include ultraviolet (UV) blocking materials that may in certain circumstance even damage the underlying window to which they are applied. As such, it is desired to avoid having the UV blocking film contact the window directly.
Also, such window film sheet structures are typically provided with an adhesive layer. The adhesive layer is exposed following removal of a low adhesion release liner and mounted to a window casement or the like. As noted, cutting and installing such thin films tends to be problematic due to their very flexible nature not to mention the adhesive layer sticking to itself in the process. As such, adhesives tend to further limit their uses, especially in do-it-yourself applications.
Attempts have been made to space transparent films incrementally from windows in order to improve the R-value associated with the windows. An R-value is a rating utilized to measure how well insulation can resist heat flow. The higher the R-value, the greater the insulating properties and the slower heat and cold flows through it. Such films provide for reduction in heating costs. However, while window films are beneficial they have not necessarily been successfully adapted for use in thermally insulating transparent panels, such as windows. In part, this is due to the films being very thin, such as in the order of about 1 mil to about 4 mil. Typically, when applied to a frame for mounting the same, they cannot be kept planar over a frame opening. This is due primarily to their very flexible nature (i.e., they cannot sustain their dimensions). Accordingly, physical distortions of the films may arise and their optical properties are compromised. Because these films tend to be heat shrinkable, one typical approach for addressing their very flexible nature is to apply heat locally on the film. This is usually done by a hair dryer, heat gun, or other similar device. Heating causes the film to shrink over the frame opening, whereby it assumes a taught and generally planar orientation. As such, visual distortions thru the film are minimized and the appearance of the film over the window appears aesthetic. However, when heat is applied, it is usually done after the film has been applied to the frame and the film has reached room temperature of its operating environment. In some cases, heat is applied up to 24 hours after the film has been mounted on a frame. Clearly, this additional labor and time inhibit the ability for quick and reliable mounting window film sheet structures to frames in many situations.
Also, direct application of the adhesive layers to window casements or the like inhibits reuse from heating season to heating season since the adhesive qualities tend to diminish through repeated usage. In addition, if window films are directly attached to windows, they are difficult to remove.
Thus, due to the number and complexity of steps involved in installing inherently very flexible film, along with the adhesive issues associated with installing thin window films, the prior approaches are generally considered time consuming, demanding, as well as potentially costly. These burdens are even more pronounced particularly in the do-it-yourself field, wherein a typical installer has very little experience handling these materials.
Without the foregoing issues being satisfied, the true potential of successfully using and applying window film sheet structures in a manner that: avoids optical distortions due to their very flexible and adhesive qualities causing permanent film flaws; and, may promote thermal insulation during repeated heating seasons may not be fully achieved, especially in a simple, reliable, less time consuming and less costly manner.
The present invention provides enhanced methods, apparatus, methods of making such apparatus, and a kit adapted for making frames adaptable for installing window film structures over transparent panels, such as windows in a manner representing improvements over prior art approaches.
The present invention relates generally to frame assemblies carrying films and, more particularly, to frame assemblies adapted for installing window film structures over windows of window assemblies as well as maintaining their optical properties.
The present invention provides a film frame assembly in combination with a transparent panel assembly defining an opening adjacent a transparent panel. The film frame assembly is adapted for installing window film structures over the transparent panel, the combination comprises: a frame defining a frame opening; one or more pressure-sensitive adhesive portions on at least one side of the frame and being attachable to the transparent panel assembly; and a generally flexible film sheet structure for covering the frame opening, wherein the frame comprising, a plurality of frame elements, each one having a channel that is aligned with channels of the other frame elements to thereby define a receptacle for removably receiving the film sheet structure.
The present invention provides a method of making a transparent panel film frame assembly adapted for installing window film structures over a transparent panel in a transparent panel assembly, the method comprising: providing a film sheet structure; providing a frame defining a frame opening, wherein the frame provided includes a plurality of frame elements, each one having a channel; aligning the channels of the frame elements to thereby define a receptacle for removably receiving the film sheet structure; applying one or more pressure-sensitive adhesive portions to at least one side of each of the frame elements so that the frame elements can be connected to the transparent panel assembly; and inserting the film sheet structure within the receptacle.
The present invention provides a kit that comprises: a frame defining a frame opening, wherein the frame includes a plurality of frame elements, each one having a channel that is aligned with channels of the other frame elements to thereby define a receptacle for removably receiving the film sheet structure; one or more pressure-sensitive adhesive portions on at least one side of the frame elements; and a generally planar film sheet structure for covering a frame opening, wherein the film sheet structure is generally stiff and remains generally planar when inserted in the receptacle.
The present invention provides a film frame assembly in combination with a transparent panel assembly including a transparent panel, the film frame assembly is adapted for installing window film structures over the transparent panel, the combination comprises: a transparent panel film sheet structure, a frame defining a frame opening, wherein the frame includes a plurality of frame elements, each one having pressure-sensitive adhesive portions attached to one surface for adhesively securing the frame elements to the transparent panel, and each one having pressure-sensitive adhesive portions on an opposing surface for adhesively securing the transparent panel film sheet structure thereto, whereby the transparent panel film sheet structure may provide for thermal insulation and is spaced apart from the transparent panel.
The present invention provides a method of installing a film sheet structure in a spaced apart relationship from a transparent panel, the method comprises: providing a frame that includes a plurality of frame elements for defining a frame opening; providing a film sheet structure that is sized to cover the frame opening; adhesively securing one side of each of the frame elements to the transparent panel; and adhesively securing another side of each of the frame elements to the film sheet structure so that the film sheet structure is spaced apart and may have a thermal insulating relationship to the transparent panel.
The present invention a kit that comprises: a window film, sheet structure; a frame defining a frame opening, wherein the frame includes a plurality of frame elements; a plurality of pressure-sensitive adhesive portions attachable for adhesively securing the frame elements to the window, and for adhesively securing the window film, sheet structure to the frame elements.
An aspect of the invention is the provision of method, apparatus, and kit for providing a modular frame assembly using, a window film sheet structure adapted for installing window film structures over a window assembly.
An aspect of the present invention is a method, apparatus, and kit adaptable to use window film sheet structures for installing window film structures over windows as well as maintaining optical properties of the window film sheet structures.
An aspect of the present invention is a method, apparatus, and kit that achieve the foregoing in a manner that minimizes significantly the costs and labor associated with making such modular frame structures perform as noted.
Another aspect of the present invention is a method, apparatus, and kit that achieve the foregoing in a manner that increases significantly the reliability and ease of installing, such as window film sheet structures particularly in a do-it-yourself environment.
An aspect of the present invention is a method, apparatus, and kit that achieve the foregoing in a manner that obtains the benefits of installing window film structures, over window film assemblies by using window film sheet structures that do not require adhesives.
The aspects described herein are merely a few of the several that can be achieved by using the present invention. The foregoing descriptions thereof do not suggest that the invention must only be utilized in a specific manner to attain the foregoing aspects.
These and other features and aspects of one aspect of this invention will be more fully understood from the following detailed descriptions of the preferred embodiments. It should be understood that the foregoing generalized descriptions and the following detailed descriptions are exemplary and are not restrictive of the invention.
The words “a”, “an”, and “the” are utilized interchangeably with “at least one” to mean one or more of the elements being described. By using words of orientation, such as “top”, “bottom”, “overlying”, “front”, “back” and “backing” and the like for the location of various elements in the disclosed articles, we refer to the relative position of an element with respect to a horizontally-disposed body portion. It is not intended that the disclosed articles should have any particular orientation in space during or after their manufacture.
Reference is made to
One cross-sectional view of a frame element 12 is shown in
As illustrated in
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In
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Reference is made to
In one illustrated embodiment, the window film sheet structure 16 is a window film structure that includes a removable clear liner 16a joined to a film base structure 16b through a pressure-sensitive adhesive layer (not shown). While the window film sheet structure 16 noted typically has its clear liner removed, this invention envisions not removing such so as to impart stiffness, in this manner, the window film sheet structure 16 will retain its planar relationship and avoid being too flimsy and creasing so as to cause permanent flaws therein. Instead of removing the clear liner 16a, it will remain with the base structure 16b. Accordingly, the film will have a thickness in a range that will provide the requisite stiffness. This window film sheet structure 16 may be of the solar window film type. The clear liner 16a can be made of polyester, vinyl, or suitable material, the film base structure 16b can be made of a suitable polypropylene or polyethylene material. Other suitable materials polymer sheet materials may be used. Whatever materials are used the collective thicknesses should be sufficiently thick for the window film sheet structure 16 to be flexible and yet stiff enough to hold its dimensions during use. One commercial version of such a film structure is Prestige™ that is commercially available from 3M Company, St. Paul, Minn. This film has a base structure that includes a polyester material having an adhesive thereon, and a clear liner made of polyester. Another example of a window film sheet structure that, may be used, is Scotch® Tint film that is commercially available from 3M Company, St. Paul, Minn. The thickness of such window film structures may be in the range of about 2 mil to about 10 mil.
Another embodiment contemplates using a window film structure with an additional transparent layer that is added to a window film structure that may be too thin to provide stiffness of the kind described herein. In this regard, the additional layer serves to increase thickness of the window film sheet structure so that the latter will obtain desired stiffness. The additional layer maybe co-extruded with the window film base structure. The additional layer is essentially added to provide stiffness to the overall window film sheet structure. In this manner, the window film sheet structure will tend to retain its dimensions and planarity, such as when mounted to the film frame. The additional layer is not intended to add optical properties that affect the functioning of the window film sheet structure. Alternatively, additional layers may have materials added thereto, in any suitable manner, so as to alter the optical properties of the overall window film sheet structure.
The window film sheet structures may be selected from a group of window film structures that comprises solar window film, privacy window film, anti-graffiti film, security window film, graphic design film, frosted finish film or any combination thereof. The foregoing films may reflect ultraviolet and infrared solar energy as well as possess other known characteristics.
Provision is made for a kit 50 (see
Reference is made to
Reference is made back to the window 120. As noted, it is one of many kinds of substrates that, can be laminated according to one aspect of this invention. The window 120 may be any type made of any suitable material, such as glass, transparent plastics or the like. Additionally, the window 120 can have any number of suitable optical, chemical and mechanical properties. The window 120 is surrounded by a suitable window assembly 130, such as the kind utilized for residential purposes. It will be appreciated that there exists a wide variety of window assemblies that may be utilized and the type depicted is for illustration purposes only.
As seen in
The materials selected for the template blank sheet 110 may be durable to allow reuse. The installer can cut along or adjacent the creases 132 to thereby enable accurate sizing and shaping functions to be carried out. The template blank sheet 110 may be comprised of one or more layers of a pliable material selected from a group consisting of but not limited to paper, non-woven materials, and suitable sheet polymers. The template blank sheet 110 may have any suitable thickness. Thickness ranges are typically about 5 to 10 mils, but may exceed such range depending on the material being used. The foregoing materials and/or thicknesses are selected so that the template blank sheet 110, when formed into the mounting tool apparatus 112 (
In
An installer can first attach the double-sided pressure sensitive adhesive stripes 142, unrolled from a web roil 162 (
The window film sheet structure 114 is utilized for changing the optical properties of the underlying window 120 as well as may potentially increase an R-value of the window assembly. The window film sheet structure 114 can be the same as described in the preceding illustrated embodiment. The illustrated embodiment may use the window film sheet structure 114 as described above in FIG 8.
Reference is now made to
Reference is now made to
Prior to installing the window film sheet structure 114, the present invention contemplates use of elongated spacer elements 122 made of any suitable material, such as molded plastic. The spacer elements 122 are thin and elongated stripes which form a frame assembly 145 (
As shown in
To implement the foregoing a kit 170 is provided that includes: template blank or sheet 110, window film sheet structure 114, spacer elements 122, a cutting tool 126, adhesive stripes 142, 149, a roll 156 of wood grained finishing tape 158, and a set of appropriate instructions (not shown).
The window film sheet structure is used for changing the optical properties of the underlying window. Window film sheet structures are generally transparent plastic and/or metallized film sheet structures that are applied as thin layers to transparent panels, such as glass windows. Window film sheet structures are available in many different compositions for bringing about varying effects on the optical and mechanical properties of the underlying transparent panels. The present invention is not limited by the kind of window film sheet structure to be used.
The above embodiments have been described as being accomplished in a particular sequence. It will be appreciated that such sequences of the operations may change and still remain within the scope of the invention. Also, other procedures may be added.
One aspect of this invention may take on various modifications and alterations without departing from the spirit and scope. Accordingly, one aspect of this invention is not limited to the above-described embodiments, but is to be controlled by limitations set forth in the following claims and any equivalents thereof.
One aspect of this invention also may be suitably practiced in the absence of any element not specifically disclosed herein. All patents and publications noted above, including any in the Background section are incorporated by reference into this document in total.
The present application is related to co-pending and commonly assigned U.S. patent applications: U.S. patent application (Attorney Docket No. 62687US002) entitled “Window Film Assembly And Method of Installing”; U.S. patent application (Attorney Docket No. 62688US002), entitled “Window Film Frame Assemblies For Installation Over Windows And Methods”; U.S. patent application (Attorney Docket No. 62690US002) entitled “Apparatus For Mounting Laminates On Substrates And Methods Thereof”; all of which are filed concurrently herewith.