This disclosure relates to windows and window framing, particularly for reducing or avoiding damage to windows in homes in coastal areas prone to high winds and hurricanes and in other areas where concerns for the physical security of windows is elevated.
In the past, shutters have been used to protect windows from the strong winds and the driving rains associated with storms and hurricanes. In more recent times, homeowners have used sheets of plywood to cover windows and doors to protect against flying debris. In areas where physical security threats are elevated, homeowners can be concerned about window breakage and attempted break-ins.
Window damage from weather occurs in areas that are often along a seacoast, areas that are scenic and desirable to live, notwithstanding the occasional severe weather. Hurricanes are a particular problem because of the combination of high winds, heavy rainfall, and hurricane paths that are difficult to predict accurately. Current measures taken to protect windows as storms approach such as attaching plywood over windows are time-consuming and the homeowner may need to evacuate before completing the task if the storm accelerates its ground speed.
In areas where physical security is a concern, the owner has to balance the increased security of installing permanent bars or other window covering against the cost of installation, the effect on appearance, and the impact on the view through the window.
Improvements in glass and protective glass coatings have made it possible to obtain window glass that is much more resistant to scratches and breakage. Improvements have also been made in panels for covering windows in advance of storms, such as panels that can be installed more easily, are translucent, and that help to reduce injury and protect property. These measures, however, come at a cost.
Providing protection for vulnerable windows of a modern home near coastal areas, especially one that may have many windows and glass doors for better enjoyment of the view, can become expensive. Moreover, “outdoor architecture,” common to coastal areas, favors more natural light and access to fresh air.
The need for window protection is not uniform even in the same home. With respect to hurricane protection, local building codes, for example, may use more protection for windows closer to the ground and less protection, or none at all, for windows in upper floors. Security protection for windows closer to the ground in urban areas is also greater than for windows higher up.
In locations where extreme weather is a concern, windows can be protected by temporary exterior panels or impact resistant glass; and where security is a concern, security glass, screens or bars may be used. Impact resistant glass is comprised of two sheets of glass bonded together with a protective interlayer. Laminated glass is the primary hurricane barrier used in impact resistant windows. Laminated glass is also used in the windshields of cars. In addition, the interior of a building and its occupants may sometimes be protected by interior panels or impact resistant glass, or both. Windows elevated from the ground so as to necessitate a ladder for installation of exterior panels may be protected by interior panels which are easier to install and protect the occupants, if not the window itself, in the event it is shattered by debris.
Full protection for every window may be prohibitively expensive. Moreover, the aesthetics of the home exterior may be addressed and uniformity of window appearance incorporated as part of those aesthetics. Accordingly, there remains a need for better ways to provide effective protection for windows in areas vulnerable to extreme weather and for security protection. Protection that is pre-installed or quickly and easily applied, is effective in extreme weather and increase security, and is available at reasonable overall cost and does not adversely affect the appearance of the home or office.
According to its major aspects and briefly recited, herein is disclosed a window system that includes a customizable window frame permitting different levels of protection against severe weather or physical security threats using windows that may have the same external appearance of window frame. The inner structure of the frame and the type of glazing can be customized for the windows in the home or building so that the windows may provide a preferred and preselected levels of protection from severe weather or security threats. In addition, the exterior style of the windows and the doors can be identical and can be separately customized with different levels of protection for greater physical security and against severe weather.
For example, the window or door frames on the lower levels of a multi-level home or office may have extra protection against high winds, blowing dirt, sand and debris. That extra protection can be provided by impact resistant glass and by window frames and door frames that permit easily-attached exterior panels. Upper floors in the same home or office building may have less protection as appropriate or no protection. Protection for windows and doors on one side of the home or office can be greater on, for example, the windward side, than for the windows and doors on the other side. Regardless of the customization of different windows, the external appearance can be uniform.
The ability to customize protection for a window and door is achieved by arranging for the extrusion that will be used to form the frame of the window or door to optionally receive one or more separately-made extrusions by inserting those extrusions into the receptor channels. The inserted extrusions, which may be screw bosses, in addition to adding strength and rigidity to the frame, cooperate with panels or other exterior or interior coverings to enable the occupant to quickly and easily attach interior protection. These coverings may be temporary panels or fabrics that provide protection over the glazing against broken glass. Finally, glass having higher impact resistance or scratch resistance can be specified when the window or door is such that exterior panels and fabrics cannot be easily or safely installed.
In addition, the separately-extruded inserts may be inserted into the jambs only, the header and the sill and not into the jambs, or all sides of the frame made of the header, sill and two jambs, such as for second story windows. Jambs are typically longer as they determine the vertical dimension of the window. Therefore the cost making and inserting shorter extruded inserts of the headers and sills, as measured in price per linear foot or meter of extrusion, will be less than if the inserts were added to the four components of the frame or to the jambs.
Moreover, separately extruding the inserts for insertion into the receptor channels if and where used reduces costs compared to extruding the frame components with an co-screw boss. The dies are simpler and the additional strength provided by a screw boss insert is applied where used.
Accordingly, an architect or builder can evaluate the relative level of safety protection for the window of a designed structure and specify the level of protection appropriate for that window at the time it is ordered. The windows of the finished structure can nonetheless have the same external appearance and style, as determined by the frontal appearance of the window frame, despite differences in robustness of the windows against severe weather.
When a storm approaches, the owner simply applies panels to the more vulnerable windows, such as those to the windward side, for example, and perhaps to windward windows higher up that are easily reached, such as those opening to an upstairs balcony or deck. The owner may attached panels on the insides of upstairs windows as a precaution against wind-blown debris breaking those windows.
An advantage of being able to customize the protection provided by windows, doors and other openings of a building is that the overall cost of protection is reduced by applying greater window and door protection to those windows and doors that are more vulnerable and less protection or none to those windows that are not likely to be damaged. Being able to customize the protection provided by different windows and doors of a building and provide a pleasing and, if desirable, a uniform external appearance is also an advantage.
Another advantage is that the use of insertable screw bosses for those windows that need protection as opposed to extruded screw bosses used where useful and not in every header, sill, and jamb whether used or not.
These and other advantages will be apparent to those skilled in the art of window design and installation particularly for buildings in areas where security or severe weather is a concern.
U.S. patent Ser. Nos. 10/604,989, 10/641,035, 8,863,452, 8,789,324, and 8,438,802, assigned to the assignee of the present application, are incorporated herein in their entirety by reference.
The term “extruded” is used herein for convenience but jambs, sills and headers may be formed in any way customary in the industry, for example, pultruded.
The term “frame” as used herein, and used in connection with a window, such as a “window frame,” refers to the structure that is attached to a building where a hole has been made in the building for receiving that window (or receiving a vent or an appliance such as a wall-mounted air conditioner). The frame is typically a four-sided structure that is sealed to the opening made for it and that holds the window, vent, or appliance.
The word “building” will be used here for convenience to mean any structure with openings in its walls. The structure includes by way of example, and not of limitation, homes, apartment buildings, and office buildings. The word “walls” refers to barriers such as walls, ceilings, and doors that are positioned between the inside of the building and its outside. The word “window” will be used to refer to an opening in a wall, as defined herein, such as a window in a wall, a window in a door, a skylight in a ceiling, or a sliding glass door in a wall, where the window has a covering that admits light, unlike the opaque material of the wall, door frame, and roof.
The term “customizable” is used herein to describe the ability to choose from a selection of options among protective mechanisms that protect the interior of a building from physical damage as a result of severe weather or a security threat outside the building. The features selected from among the options are added to a co-extruded frame of a window as the window is being manufactured. These protective mechanisms improve the ability of the window to withstand increased stress from a security threat, high winds, heavy rain, and flying debris or hail.
The term “astragal” refers to hardware that is used on a pair of doors to seal the gap between the doors when they are closed. The astragal is fastened to the doors themselves on the sides of the doors that meet, rather than to a separate door frame.
A “screw boss” is a physical structure that grips the threads of a screw being driven into it so that, once the screw has been inserted into or through the screw boss, the screw boss resists the removal of the screw more when the screw is pulled than when the screw is unscrewed. An insertable screw boss is a screw boss that has been separately co-extruded so that it can be inserted into a channel and is otherwise functionally the same as a screw boss co-co-extruded as an integral part of that channel.
A window frame or astragal may be better able to hold a panel if the window frame or astragal as disclosed herein is customized by inclusion of a co-co-extruded or inserted screw boss, which provides an effective way to hold the screws for attaching panels over a window or a glass door. A panel may be attached to the window or door on the interior of a building or to the building exterior.
Protection for windows higher off the ground, namely, by interior panels may often be more practical than panels installed on the exterior of the window when the window is located higher on the building. Indeed, building codes specify less protection for windows over 30 feet above the ground because they are less subject to damage in high winds. Thus, architectural consistency among the present window and door frames may be preserved so they have same style and frontal appearance and be made from the same a vinyl extrusion, and the glass in the windows will appear to be the same regardless of whether it is impact resistant glass, safety glass or ordinary window pane glass.
The frame of the present system is customized in its interior before the windows are made and may receive an inserted screw boss in the frame elements just prior to assembly of the window frame or during extrusion, according to a specification provided for that window. There may be one specification for the robustness of the windows on the ground floor, for example, and another one for those on the second floor, particularly if reaching the higher windows to apply panels would be difficult or dangerous. Upper windows may have co-co-extruded or inserted screw bosses in an interior channel for the attachment of interior panels rather than in the receptor channel for attaching exterior panels, or may have no screw bosses at all, for example, if intended for windows over 30 feet from the ground.
For those windows that would be covered by panels on the approach of bad weather or when there are security concerns, the frame profile will have the desired aesthetic exterior features as the frame of any other window of that building. However, there may be a second, interior, screw boss that may have been inserted into a receptor channel in the frame profile to provide additional holding power for screws that are to hold a panel to the window and possibly for use in an interior channel for holding an interior panel.
In another example of customized window protection, the downstairs windows may be customized for receiving screws to hold panels across the windows, and the upstairs windows may be customized to hold panels on the interior of the window or customized with more robust glass such as safety or high-impact glass or security glass that is more resistant to breakage.
In a variation of the foregoing example, the upstairs window frames and the downstairs window frames may be customized to hold panels on the inside of the window, and the downstairs windows may be customized to hold panels outside the windows.
The present system allows for customization of what may otherwise appear to be uniform-looking windows by enabling attachment of panels inside the window or outside using frames with co-co-extruded screw bosses or inserted bosses or no screw bosses, and by selecting glazing having different levels of strength and scratch-resistance such as impact resistant glass or security glass, as preferred, for protecting windows of the home or building. Yet the windows have a uniform external appearance.
Turning now to the figures,
First lineal profile 20, as shown in
The top of the
Linear profile 20 has two other features. On left side 22 of first lineal profile 20, as indicated by an arrow pointing to an entrance, referred to herein as a receptor channel 32, is a co-co-extruded first screw boss 34 in a receptor channel 36. These features, receptor channel 32 and first screw boss 34, facilitate attachment of a panel or other protective exterior covering for protection of glazing held by the frame at recesses 26, and is co-co-extruded as part of first linear profile 20. A screw or other fastener may be driven left to right in left side of
A screw boss is a device that may be made separately from first lineal profile 20 by extrusion, just as first lineal profile 20 is made, and which screw boss presents a series of barriers across is long dimension, as see in
First lineal profile 20, second lineal profile 20′, and third lineal profile 20″ result from extrusions using dies that produce the specific profiles shown in
Between the exterior and interior surfaces of first lineal profile 20, second lineal profile 20′, and third lineal profile 20″ are functional feature designed to make first lineal profile 20, second lineal profile 20′, and third lineal profile 20″ more rigid with less material. Other aspects of the structure of first lineal profile 20, second lineal profile 20′, and third lineal profile 20″ are functional in that they are intended to hold to the wall of the structure, such as nail fin 30 or hold the glazing.
Screw boss 50 and screw boss 52 are separately extruded as opposed to being co-extruded. The term “co-extruded” is used herein to mean that one die is used to form the profile and the screw boss, and contrasts with separate extrusion of profile and screw boss using separate extrusion dies.
Compare
First screw boss 50 and second screw boss 52 are modified from first screw boss 34 and second screw boss 42. First screw boss 50 and second screw boss 52 may include additional structure in order to fill—or brace themselves—within the interior of receptor channel 36 or second channel 38, so that they remain in place during handling, assembly, storage, shipping and insertion of long screws.
Thus, when multiple windows of a building may have different levels of window protection and yet look the same from the exterior, flexibility in providing that particular level for the windows can be achieved by the use of inserted screw bosses for specific windows. Some windows do not need impact resistant glass, and some windows do not need co-extruded internal and external screw bosses, so the ability to decide whether to add screw bosses as the windows are built enables considerable flexibility and economy in accommodating the individual needs for window protection.
Also, some components of a frame do not need to contain screw bosses. Inserting screw bosses in headers and sills uses shorter segments of screw bosses then when screw bosses are inserted in the jambs. This is a feature of the present disclosure. In addition to flexibility in choosing whether to insert screw bosses or not in any particular window frame, there is also the flexibility in determining if screw bosses are to be used in the header and sill of a frame rather than in the jambs, or in the jambs and not in the header and the sill.
In addition to windows and other framed openings, doors may also provide protection from damage from severe weather.
Referring now to
Horizontal cross-section 62 (
A variation of the use of co-extruded and inserted screw bosses enables application of the present disclosure to “astragal” bi-directional, sliding glass doors in order to enable them to receive protective panels. Two versions of astragal closures are illustrated in cross-sectional drawings of
The present lineal screw boss extrusion, made either as part of a larger lineal or made separately and inserted after the fact, can also be adapted for use with glass block windows.
Sliding door 136 moves and a fixed door 138 that does not slide or otherwise move are confined in frame 134. Sliding door 136 has door handles 146 for opening sliding door 136.
Sliding door 136 includes its own frame 148; fixed door 138 also includes its own frame 150. Glazing 144 in sliding door 136 and fixed door 138 defines the boundary between the interior side 140 and the exterior side 142 of sliding door 136.
In
Window 170 is a double-hung window, as seen in
In
Finally, as shown in
In
In
Finally, in
The present disclosure thus teaches that the same frame profile that includes a receptor channel can include an co-extruded screw boss or an inserted screw boss or be left empty depending on the exposure of the individual windows to severe weather or other source of impact and the need for a stronger hold on the panel fasteners. The same frame profile that includes a receptor channel facing outward can also include a receptor channel facing inward so that an interior panel can be used to provide temporary protection to the occupants of a room, especially if that window will be mounted high off the ground where exterior panel attachment would be risky to the installer or if the severe weather arrived before exterior panels could be attached. In urban areas, vandalism may be more of a concern than severe weather, and other window protection can be substituted for panels and fastened in the same manner as panels. Accordingly, the present disclosure teaches how the windows of a home or building can be customized for either the severe weather of a coastal environment or the risks of an urban environment while having a pleasing uniform external appearance
This application claims the benefit of previously filed U.S. provisional patent application Ser. No. 63/044,576, filed on Jun. 26, 2020, the contents of which is hereby incorporated by reference in its entirety as if fully reiterated herein.
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