Patent Grant
11136816
A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever. The following notice applies to the data and drawings that form a part of this document: Copyright Marvin Cedar Company (d/b/a Marvin Windows and Doors); Warroad, Minn. All Rights Reserved.
This document pertains generally, but not by way of limitation, to fenestration assemblies and lineal components of fenestration assemblies.
Fenestration assemblies including window and door fenestration assemblies include one or more frames. For instance, double hung and door fenestration assemblies include panels (e.g., sashes or doors) movably coupled with a peripheral frame. In at least some examples, each of the panels includes its own frame coupled with a glazing unit, such as a pane of glass.
Some examples of fenestration assemblies include frames constructed with aluminum, steel or the like. For instance, lineal aluminum or steel components are cut to length and assembled to form the frame. In other examples, the frames are constructed with vinyl or polyethylene. In a similar manner to metal components, lineal vinyl or polyethylene are cut to length and assembled to form the frame.
The present inventors have recognized, among other things, that a problem to be solved can include increasing the strength of fenestration assemblies while at the same time also enhancing thermal insulating properties of fenestration assemblies. Fenestration assemblies including metal frames (e.g., aluminum, steel or the like) are robust assemblies that are resistant to warping, fatigue or the like. Accordingly, metal frames are durable and well suited for large fenestration assemblies including windows and doors that warrant additional rigidity to resist warping or fatigue. In extreme temperatures (e.g., summer, winter or other non-seasonal temperature extremes) the thermal conductivities of metal frames readily transmit heat. For instance, in the winter interior heat is readily transmitted to the exterior of a home through the frame or one or more metal components of the assembly including metal pane spacers between multiple panes of glass. While in the summer exterior heat is readily transmitted through the frame (or metal pane spacers) to the interior of the home.
Optionally, insulating foam, fillers or the like are provided within cavities of the metal frames. While providing some thermal insulation, the metal of the frame extends between the interior and exterior and continues to provide a conductive route for heat between the interior and the exterior (e.g., a route having a relatively high overall heat transfer coefficient (U), high thermal conductivity (κ) or the like). The temperature gradients between the exterior and interior of the fenestration assemblies promote heat transfer along the conductive route, and accordingly decrease the efficiency of heating or cooling a space, such as a room, multiple room building or the like.
In some examples, insulation features, such as bars, plates or the like are interposed between interior and exterior metal frame components. The interposing insulation features intercept and throttle conducted heat, and accordingly decrease the overall heat transfer coefficient (U) of the fenestration assembly. The interposing insulation features also interrupt the rigid structure of the fenestration assembly. Instead of a robust metal frame extending throughout the fenestration assembly the insulation feature is sandwiched between thinner component frames, and the overall modulus of elasticity of the fenestration assembly (a characteristic indicating rigidity) is decreased. To offset the decreased modulus of elasticity one or more of the component frames are enlarged (e.g., have a greater depth), wall thicknesses are increased or the like increasing the weight and profile of the fenestration assembly.
Further, the inclusion of interposing insulation features facilitates variations in thermal expansion between separated frame components. Accordingly, during cold or hot temperatures one of the interior or exterior frame components expands at a different rate than the other frame component. In some examples, the differential in expansion generates loud popping noises in a home. And in other examples the expansion differential warps the fenestration assembly or damages the insulating feature or frame components through the application of shear.
In other fenestration assemblies including vinyl or polyethylene frames the overall heat transfer coefficient (U) is improved compared to metal fenestration assemblies. The vinyl or polyethylene frames, however, have a less rigid structure (e.g., smaller Youngs Modulus) than the metal counterpart frames, and accordingly are less suited for larger fenestration assemblies that use structurally robust framing to resist weight based warping or fatigue. Accordingly, the fenestration assemblies are reinforced with increased wall thicknesses, larger profiles or the like that increase the weight and profile of the fenestration assemblies.
The present subject matter helps provide a solution to these problems with a fenestration assembly including a fenestration frame having a frame core that receives a glazing unit therein. The frame core includes a composite material having robust structural characteristics and thermal insulating characteristics. In one example, the frame core includes a polyurethane impregnated with filaments, such as glass fibers. Optionally, the polyurethane (urethane resin) and filaments are produced in a lineal manner through one of pultrusion or extrusion. The frame core including these composite materials includes characteristics, in one example, such as a modulus of elasticity of seven million pounds per square inch (psi) or more, and thermal conductivity (κ) of 4.0 Btu in/(hr ft2° F.) or less, 3.0 to 4.0 Btu in/(hr ft2° F.), 3.0 Btu in/(hr ft2° F.) or the like.
The frame core (one or more of the assembly frame, panel frame or the like) includes a core wall that extends continuously between a core exterior face and a core interior face. The glazing unit is retained between the core exterior and interior faces. The modulus of elasticity (e.g., seven million psi or more) facilitates the use of smaller profiles without structural reinforcements, such as increases in profile sizes or increasing of wall thickness. Further, because of the thermal conductivity of the frame core material (e.g., 4.0 Btu in/(hr ft2° F.) or less or the like) the frame core does not require intervening insulating features, such as bars, plates or the like between frame components. Instead, the frame core extends continuously between the core interior and exterior faces, maintains its mechanical characteristics (e.g., seven million psi or more modulus of elasticity), and accordingly maintains a narrow profile while at the same time providing an insulating fenestration assembly. Further, because of the relatively low thermal conductivity of the frame core as well as the other heat diverting and throttling features described herein, the fenestration assembly provides a corresponding and relatively low heat transfer coefficient (e.g., 0.3 or less).
Additionally, example fenestration assemblies described herein couple the glazing unit within the frame core with one or more glazing clamps. The glazing clamps include deflectable arms (e.g., a polymer living hinge or the like) that engage the glazing unit and clamp the glazing unit between the deflectable arms and the frame core (e.g., a core flange). In another example, a glazing cap covers the glazing clamps and provides a clean aesthetically appealing finish to the fenestration assembly. In some examples, the glazing cap is constructed with a metal, such as aluminum, that is formable (machined, extruded, forged or the like) with sharp corners, decorative profiles or the like. The glazing gap is coupled with the frame core proximate the core interior face and coupled over the glazing clamp. The glazing cap optionally couples along the glazing unit with a seal, such as a gasket, weather stripping or the like to provide an insulated coupling between the cap and the glazing unit. In contrast to the metal glazing cap, the glazing clamp includes thermal insulating materials (relative to metal, such as aluminum). The glazing clamp includes a clamp end engaged with the glazing unit, for instance with point loading or linear loading (e.g., along the clamp end edge).
In one example, the frame core described herein (e.g., having a core wall and one or more intervening cavities between the interior and exterior of the assembly) and the glazing clamp are part of a thermal isolation envelope. The thermal isolation envelope thermally isolates features of the assembly that have relatively high thermal conductivities such as metal components, for instance the metal glazing cap described herein and one or more metal pane spacers included with glazing units (e.g., insulated glazing units or IGU, insulated glass or IG) to separate glass panes and form gas or vacuum cavities. The thermal isolation envelope instead directs heat transfer around features having high thermal conductivities (e.g., metal pane spacers, metal glazing caps or the like) and through the frame core. Because the frame core includes one or more of a core wall and intervening frame cavities, is constructed with composite materials having a relatively low thermal conductivities (e.g. 4.0 Btu in/(hr ft2° F.) or less) the heat directed through the core walls of the frame core and delivered between the interior and the exterior of the fenestration assembly is throttled to enhance the retention of heat in a building (e.g., in cold weather) and conversely minimize the ingress of heat to the building (e.g., in warm weather). Further, the glazing clamp includes thermal insulating materials, such as polyurethane, polyethylene or the like and is engaged with the glazing unit with point or linear loading to further throttle heat transfer between the glazing unit and the interior portions of the assembly. Additionally, the indirect coupling of the metal glazing gap with an intervening seal, such as a gasket or weather stripping, isolates the metal glazing cap while the glazing clamp provides the majority of the force retaining the glazing unit in place. Accordingly, the thermal isolation envelope of the fenestration assembly thermally isolates the interior of a fenestration assembly from the exterior while at the same time maintaining a mechanically robust assembly having a relatively narrow profile (measured from the inner perimeter adjacent to a daylight opening to the exterior fenestration perimeter proximate the frame of the rough opening). For instance, the thermal isolation envelope facilitates narrow profiles in the context of direct glaze fenestration assemblies of 1.0 to 2.0 inches, casement fenestration assemblies of 2.5 to 3.5 inches, and door assemblies of 3.5 to 5.0 inches. Further, while providing these narrow profiles the wall thickness for the frame core (e.g., extruded or pultruded walls) is between 0.06 and 0.150 inches.
This overview is intended to provide an overview of subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the disclosure. The detailed description is included to provide further information about the present patent application.
In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
Referring again to
As described herein, the frame core 104 is, in one example, constructed with a polymer having one or more types of filaments. For instance, in one example, the frame core 104 includes a monomer resin such as a urethane resin having glass filaments or fibers included therein. The combination of polymer (e.g., polyurethane) and filaments (e.g., glass filaments) facilitates the production of a frame core 104 having a narrow wall profile that also provides robust structural integrity to the fenestration assembly 100. For example, the frame core 104 includes a Young's modulus of 7,000,000 psi or the like. Additionally, the frame core 104 has a wall thickness of between 0.06 and 0.150 inches while providing example assembly profiles of 1.0 to 2.0 inches for a direct glaze fenestration assembly, 2.5 to 3.5 inches for a casement fenestration assembly, and 3.5 to 5.0 inches for a door fenestration assembly.
Additionally, and as described herein, the frame core 104 constructed with a polymer and one or more filaments included in the polymer provides a thermal conductivity to the fenestration assembly 100 of approximately 3.0 Btu in/(hr ft2° F.) or less. In another example, the thermal conductivity for the fenestration assembly 100 includes a thermal conductivity between 3.0 and 4.0 Btu in/(hr ft2° F.) and, in still another example, the fenestration assembly 100 includes a thermal conductivity of approximately 4.0 Btu in/(hr ft2° F.). The fenestration assembly 100 (and other examples described herein) achieve these thermal conductivities while at the same time maintaining the modulus elasticity of around 7,000,000 psi or more. In another example, the overall heat transfer coefficient (U) of the overall fenestration assembly 100 with the materials described herein is approximately 0.31 or less and is based on the materials used with the frame core 104 as well as components of the frame core (e.g., narrow core walls, tortuous paths between the interior and exterior, cavities or the like).
Referring now to
Referring again to
As further shown, the fenestration assembly 200 includes one or more glazing units 210 provided in one or more of the panels 208. For instance, a fenestration frame 202 associated with each of the panels 208 surrounds the glazing units 210. As with the previous fenestration assemblies 100, 120, the fenestration assembly 200 includes one or more frame cores 204. In the example shown in
As further shown in
As further shown in
Referring again to
Optionally, another cap such as a panel cap 350 is, in one example, coupled along the glazing cap 320. In this example, the panel cap 350 is coupled with corresponding portions of the peripheral frame 342. The panel cap 350 along with the glazing cap 320 provides a decorative appearance to the fenestration assembly 100, for instance, proximate to or along the core interior face 300. For instance, as shown in
The frame core 104 of the fenestration panel 108, as previously described, includes a core wall 304 extending continuously from the core exterior face 302 proximate to an exterior environment to the core interior face 300 proximate to an interior environment. The core wall 304 provides a mechanically robust and continuous structural component extending from the exterior to the interior of the fenestration assembly 100 that supports the remainder of the fenestration assembly 100 without interruptions, for instance for insulation blocking or the like. For example, the frame core 104 provides a structurally robust frame component having a Young's modulus of approximately 7,000,000 psi or more. Additionally, the frame core 104 is constructed with a polymer, such as polyurethane, having one or more types of filaments therein to enhance the overall structural integrity of the frame core 104 and the fenestration assembly 100.
Additionally, the frame core 104 and its associated core wall 304 provides a circuitous path for heat to travel between the core exterior face 302 and the core interior face 300. For instance, the various components of the core wall 304 extend in lateral as well as interior to exterior directions to thereby slow the conduction of heat through the core wall 304 in a tortuous manner. Additionally, each of one or more of metal components of the fenestration assembly 100 such as the glazing cap 320, pane spacer 312 and the like are isolated from each other to thereby further throttle heat transfer through the fenestration assembly 100. For instance, the frame core 104 isolates each of these components from other proximate metal components. As shown, for instance, in
In another example, the peripheral frame 342 including, for instance, the installation flange 340 configured for installation by way of fastening or the like to a rough opening of a building is constructed with a frame core similar in at least some regards to the frame core 104 associated with the fenestration panel 108. For instance, the peripheral frame 342 includes a frame core constructed with, but not limited to, a polymer such as polyurethane and interstitial elements such as glass fibers or the like that provide robust mechanical characteristics to the peripheral frame 342 while at the same time throttling heat transfer.
As further shown in
As further shown in
As previously described, the frame core 124 provides a thermal isolation envelope that extends continuously from the exterior of the fenestration assembly 120 to the interior of the fenestration assembly 120. The thermal isolation envelope of the frame core 124 isolates components of the fenestration assembly 120 having higher thermal conductivities, such as the pane spacer 412, glazing cap 404 or other components including metal or other higher thermal conductivity materials. The thermal isolation envelope isolates these components and directs heat transfer away from the components, for instance, through the core wall 400. As previously described, the core wall 400 has a narrow cross sectional profile and includes a tortuous route between the interior and exterior portions of the assembly, such as one or more of lateral and vertical (relative to the page) segments, corners or the like to provide a circuitous route for heat transfer between the interior and exterior portions. Additionally, the core cavity 406 further minimizes heat transfer by providing a void between the interior and exterior portions. Optionally the core cavity is filled with an insulation block that intercepts heat transfer across the core cavity 406 from convection or radiation and thereby further throttles heat transfer through the frame core 124. In contrast to fenestration assemblies having insulating bars, plates or the like interposed between interior and exterior metal frame components, the frame core 124 described herein is itself a thermally insulating component that extends between interior and exterior portions of the assembly and diverts heat transfer away from high thermal conductivity components, and also provides a continuous structural framework for the assembly 120.
As further shown in
As shown in
As previously described, each of the panels 208, in this example, includes a frame core 204. In a similar manner, the peripheral frame 206 of the fenestration assembly 200 also includes one or more frame cores having a similar composition to the panels 208 and accordingly providing robust mechanical characteristics described herein as well as throttling heat transfer between the exterior and interior.
The fenestration assembly 200, shown in
Optionally, the component frames 500 include panel caps 510 configured to extend across one or more cavities, recesses or the like otherwise provided in the component frame 500 for reception of a portion of the corresponding panel 208. For instance, as shown in
As further shown in
The thermal isolation envelope 600 shown in
As further shown in
As further shown in
In another example, the thermal isolation envelope 600 throttles heat transfer in the converse direction, for instance, from the core interior face 300 toward a cooler core exterior face 302 (e.g., in winter). In this example, the heat transfer from the core interior face 300 toward the core exterior face 302 is also throttled by way of the tortuous path through the core walls 304 of the frame core 104. Additionally, each of the components of the fenestration assembly 100 having higher thermal conductivities than the frame core 104, such as the glazing cap 320 and pane spacer 312, remain isolated from heat transfer otherwise directed through the thermal isolation envelope 600.
As further shown, the glazing unit 126 is, in one example, coupled in place within the fenestration assembly 700 with a glazing clamp, such as the glazing clamp 402 shown in
As previously described, one or more components of the fenestration assembly 700 are metal, for instance, one or more of pane spacers 412, the glazing cap 404 or the like. Frame cores 124 of the fenestration assembly 700 are constructed, in one example, with composite materials including, for instance, a polymer resin such as urethane and one or more filaments included with the resin such as glass fibers or the like. The frame core 124 provides a mechanically robust framework extending between the interior and exterior portions of fenestration assembly 700 while at the same time also minimizing heat transfer with the frame core 124 between the interior and exterior portions of the fenestration assembly 700.
As further shown in
In another example, the mullion system 702 includes one or more mullion caps configured to provide an interface between the component fenestration assemblies. For instance, as shown in
At 802, a fenestration frame 102 (either or both of a frame of a sash, panel or peripheral frame of the assembly) is assembled including a frame core 104. The frame core 104 includes a composite material. At 804 assembling the fenestration frame includes forming the frame core 104 from a base resin (e.g., monomer resins, such as a urethane resin) and filaments in the base resin. The frame core 104 includes a core wall 304 that continuously extends between a core interior face 300 and a core exterior face 302. As previously described herein the frame core 104 and the core wall 304 are constructed with the composite material. Optionally, the frame core 104 is formed in a continuous process including one or more pultrusion or extrusion. At 806 the frame core 104 is cut (e.g., with a band saw or other cutting device) to provide two or more components of the fenestration frame 102. At 808, the components of the frame core 104 are assembled to form the fenestration frame 102. For instance, the components are fastened together at corners or the like with one one or more of welds, adhesives, fittings or the like.
At 810, the method 800 includes seating a glazing unit 110 within the fenestration frame 102 between the core interior face 300 and the core exterior face 302. As shown in
At 812 a glazing cap 320 is coupled with the frame core 104. One example of a glazing cap 320 is shown in
Optionally, the fenestration assembly 100 includes a glazing clamp 330 that bridges between the fenestration frame 102 and the glazing unit 110 and enhances the coupling of the glazing unit 110 with the fenestration frame 102. As shown in
At 814 the method 800 includes thermally isolating one or more of the pane spacer 312 and the glazing cap 320 (both are optionally metal) from an exterior environment relative to the fenestration assembly 100. For example, the core wall 304 of the frame core 104 includes a polymer, such as polyurethane, in combination with filaments, such as glass fibers, to enhance the strength of the frame core 104. Additionally, the composite frame core 104 isolates metal components of the fenestration assembly 100 that otherwise readily transfer heat between the exterior and the interior. As described herein, the frame core 104 provides a thermal isolation envelope 600 that throttles heat transfer through the core wall 304 and instead directs heat transfer along tortuous paths, shown in
Several options for the method 800 follow. In one example, fastening the glazing unit 110 within the fenestration frame 102 includes coupling a clamp base 332 of the glazing clamp 330 with the frame core 104. A clamp end 334 of a deflection arm 336 of the clamp 330 is engaged with the glazing unit 110. The deflection arm 336 (e.g., a polymer or other elastically deflectable material) is deflected when engaged with the glazing unit 110, and the glazing unit 110 is clamped between the frame core 104 and the glazing clamp 330 based on the engagement and deflection. In another example, the glazing clamp 330 is concealed with the glazing cap 320. For instance, the glazing cap extends over the glazing clamp 330. Optionally, thermally isolating at least the pane spacer 312 includes coupling a clamp end 334 having a relatively small profile (e.g., point or lineal contact with the glazing unit 110) to throttle heat transfer between the glazing clamp 330 and components of the glazing unit 110, such as a metal pane spacer 312.
In another example, the method 800 includes forming a core flange 308 of the frame core 104, and the core flange 308 extends from a flange end 309 to the remainder of the frame core 104. The glazing unit 110 is seated within the fenestration frame 102. For example, an exterior pane 316 of the glazing unit 110 is seated along the core flange 308.
Example 1 can include subject matter such as a fenestration assembly comprising: a glazing unit including one or more translucent panes, the glazing unit having an exterior pane and an interior pane, the glazing unit extends between glazing unit edges and includes a pane spacer between the exterior and interior panes proximate the glazing unit edges; and a fenestration frame coupled around the glazing unit, the fenestration frame includes: a frame core extending around the glazing unit, the frame core includes: a unitary core wall including a composite material, the unitary core wall is hollow and extends continuously from a core interior face to a core exterior face; and a core flange as part of the core wall, the core flange proximate the core exterior face, the core flange extends over at least a portion of the pane exterior, the core flange including a flange end remote from the pane spacer; a metal glazing cap coupled with the frame core, the metal glazing cap having a cap end indirectly engaged with the glazing unit along the interior pane, the cap end remote from the pane spacer; and wherein each of the core exterior face, the pane spacer and the metal glazing cap are thermally isolated from each other with the frame core including the unitary core wall.
Example 2 can include, or can optionally be combined with the subject matter of Example 1, to optionally include wherein the frame core is a unitary component including the composite material, and the composite material includes a filament reinforced polymer extending continuously between the core exterior face and the core interior face.
Example 3 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1 or 2 to optionally include wherein the filament reinforced polymer is a glass filament reinforced polyurethane.
Example 4 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1-3 to optionally include wherein the frame core is a unitary component including a filament reinforced polymer having a modulus of elasticity of at least 7 million pounds per square inch.
Example 5 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1-4 to optionally include wherein the frame core is a unitary component including a filament reinforced polymer having a modulus of elasticity of at least 7 million pounds per square inch and a thermal conductivity of 4.0 (Btu in)/(hr ft2° F.) or less.
Example 6 can include, or can optionally be combined with the subject matter of Examples 1-5 to optionally include wherein the frame core is a unitary component including a filament reinforced polymer having a thermal conductivity between 3.0 to 4.0 (Btu in)/(hr ft2° F.).
Example 7 can include, or can optionally be combined with the subject matter of Examples 1-6 to optionally include wherein the frame core is a pultruded frame core including the filament reinforced polymer.
Example 8 can include, or can optionally be combined with the subject matter of Examples 1-7 to optionally include a glazing clamp coupled with the frame core, the glazing clamp includes: a clamp base, a deflection arm extending from the clamp base to a clamp end, and wherein the glazing unit is clamped between the clamp end of the glazing clamp and the core exterior face.
Example 9 can include, or can optionally be combined with the subject matter of Examples 1-8 to optionally include a glazing clamp having a small profile clamp end including a polymer, and the small profile clamp end is engaged with the glazing unit with one or more of point or lineal contact.
Example 10 can include, or can optionally be combined with the subject matter of Examples 1-9 to optionally include wherein the small profile clamp end having one or more of point or lineal contact with the glazing unit is configured to thermally isolate the frame core including the unitary core wall from the glazing unit and the pane spacer.
Example 11 can include, or can optionally be combined with the subject matter of Examples 1-10 to optionally include wherein the metal glazing cap includes: the cap end, a cap plate extending over the glazing clamp to the cap end, and wherein the glazing cap conceals the glazing clamp.
Example 12 can include, or can optionally be combined with the subject matter of Examples 1-11 to optionally include wherein the core flange includes a flange plate proximate the core exterior face, the flange plate extends over the glazing unit from at least one of the glazing unit edges to the flange end, the flange end laterally spaced from the at least one glazing unit edge.
Example 13 can include, or can optionally be combined with the subject matter of Examples 1-12 to optionally include wherein the flange plate extends across a portion of the pane exterior surface and covers the at least one glazing unit edge.
Example 14 can include, or can optionally be combined with the subject matter of Examples 1-13 to optionally include wherein the fenestration assembly includes at least one of a door assembly or a window assembly.
Example 15 can include, or can optionally be combined with the subject matter of Examples 1-14 to optionally include a fenestration assembly comprising: a peripheral frame having a peripheral frame core, the peripheral frame core includes a hollow peripheral core wall including a first composite material; at least one panel movably coupled with the peripheral frame, the at least one panel includes: a glazing unit having a pane exterior surface and a pane interior surface extending between glazing unit edges, the pane exterior and interior surfaces separated with a pane spacer; a panel frame including a unitary panel frame core coupled around the glazing unit, the unitary panel frame core having a hollow panel core wall including a second composite material extending continuously between a core interior face and a core exterior face; and a metal glazing cap coupled with the hollow panel core wall, the metal glazing cap having a cap end positioned over the pane interior surface; and wherein the at least one panel includes a thermal isolation envelope extending around the pane spacer and the metal glazing cap, the thermal isolation envelope includes: the unitary panel frame core extending continuously between the core interior and core exterior faces; and wherein the thermal isolation envelope thermally isolates each of the core exterior face, the pane spacer and the metal glazing cap, directs heat transfer around the pane spacer and the metal glazing cap and through the unitary frame core, and throttles the directed heat transfer through the hollow panel core wall.
Example 16 can include, or can optionally be combined with the subject matter of Examples 1-15 to optionally include wherein one or more of the first or second composite materials includes a glass filament reinforced polyurethane.
Example 17 can include, or can optionally be combined with the subject matter of Examples 1-16 to optionally include wherein one or more of the first or second composite materials includes a filament reinforced polymer having a modulus of elasticity of at least 7 million pounds per square inch and a thermal conductivity of 4.0 (Btu in)/(hr ft2° F.) or less.
Example 18 can include, or can optionally be combined with the subject matter of Examples 1-17 to optionally include wherein one or more of the first or second composite materials includes a filament reinforced polymer having a modulus of elasticity of at least 7 million pounds per square inch.
Example 19 can include, or can optionally be combined with the subject matter of Examples 1-18 to optionally include wherein one or more of the first or second composite materials includes a filament reinforced polymer having a thermal conductivity between 3.0 to 4.0 (Btu in)/(hr ft2° F.).
Example 20 can include, or can optionally be combined with the subject matter of Examples 1-19 to optionally include wherein the thermal isolation envelope includes a glazing clamp coupled with the panel frame, the glazing clamp includes a deflection arm engaged with the glazing unit at a clamp end.
Example 21 can include, or can optionally be combined with the subject matter of Examples 1-20 to optionally include wherein the metal glazing cap extends over and conceals the glazing clamp.
Example 22 can include, or can optionally be combined with the subject matter of Examples 1-21 to optionally include wherein the clamp end is a small profile clamp end including a polymer, and the small profile clamp end is engaged with the glazing unit with one or more of point or lineal contact.
Example 23 can include, or can optionally be combined with the subject matter of Examples 1-22 to optionally include wherein the thermal isolation envelope includes the small profile clamp end, and the small profile clamp end thermally isolates the unitary panel frame core including the hollow panel core wall from the glazing unit and the pane spacer.
Example 24 can include, or can optionally be combined with the subject matter of Examples 1-23 to optionally include wherein the fenestration assembly includes at least one of a door assembly or a window assembly.
Example 25 can include, or can optionally be combined with the subject matter of Examples 1-24 to optionally include wherein the frame core includes a core flange as part of the hollow panel core wall, the core flange extends to a flange end remote from the pane spacer.
Example 26 can include, or can optionally be combined with the subject matter of Examples 1-25 to optionally include wherein a flange plate of the core flange extends across a portion of the pane exterior surface and covers the at least one glazing unit edge and the pane spacer.
Example 27 can include, or can optionally be combined with the subject matter of Examples 1-26 to optionally include a mullion system along the peripheral frame core, the mullion system includes: a mullion recess extending along a stepped perimeter portion of the hollow peripheral core wall, and a mullion shoe within the mullion recess, wherein the mullion shoe includes a shoe surface flush with a stepped surface of the stepped perimeter portion.
Example 28 can include, or can optionally be combined with the subject matter of Examples 1-27 to optionally include wherein the mullion recess is a first mullion recess of a first fenestration assembly, and the mullion system includes: a mullion bridge configured for reception within the first mullion recess of the first fenestration assembly and a second mullion recess of a second fenestration assembly, and wherein the mullion bridge interconnects the first and second fenestration assemblies.
Example 29 can include, or can optionally be combined with the subject matter of Examples 1-28 to optionally include wherein the mullion system includes a mullion cap coupled between the first and second fenestration assemblies, and the mullion cap conceals the mullion bridge.
Example 30 can include, or can optionally be combined with the subject matter of Examples 1-29 to optionally include wherein one or more of the peripheral frame core or the unitary panel frame core is a pultruded frame core including a filament reinforced polymer.
Example 31 can include, or can optionally be combined with the subject matter of Examples 1-30 to optionally include a method of making a fenestration assembly comprising: assembling a fenestration frame with a frame core, assembling the fenestration frame includes: continuously forming the frame core from a base resin and filaments in the base resin, the frame core includes a core wall continuously extending between a core interior face and a core exterior face; cutting the frame core into two or more components of a fenestration frame; and assembling the two or more components into the fenestration frame; seating a glazing unit within the fenestration frame between the core interior face and the core exterior face, the glazing unit includes a glazing unit edge and a pane spacer proximate the glazing unit edge interposed between exterior and interior panes of the glazing unit; coupling a metal glazing cap with the frame core, the metal glazing cap includes a cap end positioned over the interior pane; and thermally isolating the pane spacer and the metal glazing cap from an environment exterior to the fenestration assembly with the core wall continuously extending between the core interior and exterior faces.
Example 32 can include, or can optionally be combined with the subject matter of Examples 1-31 to optionally include fastening the glazing unit within the fenestration frame with at least one glazing clamp.
Example 33 can include, or can optionally be combined with the subject matter of Examples 1-32 to optionally include wherein fastening the glazing unit within the fenestration frame includes: coupling a clamp base of the at least one glazing clamp with the frame core, engaging a clamp end of a deflection arm with the glazing unit, deflecting the deflection arm with engagement, and clamping the glazing unit between the frame core and the at least one glazing clamp according to the engaging and deflecting.
Example 34 can include, or can optionally be combined with the subject matter of Examples 1-33 to optionally include concealing the glazing clamp with the metal glazing cap coupled with the frame core, the glazing cap extends over the at least one glazing clamp.
Example 35 can include, or can optionally be combined with the subject matter of Examples 1-34 to optionally include wherein thermally isolating the pane spacer includes coupling a small profile clamp end with the glazing unit with one or more of point or lineal contact.
Example 36 can include, or can optionally be combined with the subject matter of Examples 1-35 to optionally include wherein thermally isolating the pane spacer and the metal glazing cap includes: directing heat transfer around the pane spacer and the metal glazing cap through the core wall and a core cavity within the core wall, and throttling the directed heat transfer through the core wall and the core cavity.
Example 37 can include, or can optionally be combined with the subject matter of Examples 1-36 to optionally include wherein continuously forming the frame core includes at least one of pultruding or extruding the base resin and filaments.
Example 38 can include, or can optionally be combined with the subject matter of Examples 1-37 to optionally include wherein continuously forming the frame core includes at least one of pultruding or extruding a urethane resin and glass filaments.
Example 39 can include, or can optionally be combined with the subject matter of Examples 1-38 to optionally include wherein continuously forming the frame core includes forming a core flange of the frame core, and a flange plate of the core flange extends from a remainder of the frame core to a flange end.
Example 40 can include, or can optionally be combined with the subject matter of Examples 1-39 to optionally include wherein seating the glazing unit within the fenestration frame includes seating the exterior pane of the glazing unit along the core flange.
Each of these non-limiting examples can stand on its own, or can be combined in various permutations or combinations with one or more of the other examples.
The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the disclosure can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.
In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls.
In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.
The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the disclosure should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
This application claims priority to U.S. Provisional Application Ser. No. 62/742,720, filed Oct. 8, 2018, the disclosure of which is incorporated herein in its entirety by reference.
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