Patent Application
20100083597
The invention relates to fenestration assemblies. In particular, the invention relates to an interior sash covering which gives a vinyl sash the mortise and tenon look of a traditional wood window, with an optional decorative coating, with the advantages of the strength and durability associated with vinyl. The invention also relates to fenestration assemblies containing the same. The invention is in the scope of mechanical engineering and is applicable to the fenestration industry.
Customers are increasingly demanding larger windows with a decorative finish, such as wood. Windows with an all wood assembly have the attraction of presenting an appealing wood face to the interior of the home, which in many cases is desirable and coincides with the interior design tastes of the home owner. However, the discerning tastes of a large number of home owners is also resulting in the additional request that the wood finish of the windows does not have the appearance of knots and joints. Due to the increasing demand on the lumber industry for this and numerous other applications, it is becoming increasingly difficult to harvest large quantities of clear pine and other species. Accordingly, the lumber industry cannot provide the required material at competitive pricing, making window assemblies that are constructed entirely out of wood expensive to manufacture, install and maintain.
An alternative is the use of wood veneer products in the production of windows. Window assemblies that are essentially made out of a plastic or vinyl material can have wood coating or covering elements on the interior of the window, providing for a window that is strong and reliable, as is the current standard with vinyl windows, while also incorporating the desired wood finish to appease the home owner. These products also have the economical advantage in that the assembly is not entirely fabricated from wood, thus decreasing the cost associated therewith. Furthermore, wood coating and/or covering products are currently available in a wide selection of species, free of knots, with minimally visible joints, and are thus able to accommodate most decor requirements.
One of the issues surrounding the use of wood coating or covering elements on the interior of window assemblies is that wood and various other materials that may be used as a coating or covering element do not have the same physical properties as vinyl, and thus, can not be fusion welded. However, the process of fusion welding of vinyl window frames and sashes is the industry standard. Accordingly, this is an obstacle that needs to be addressed.
There have been various incarnations within the prior art where attempts have been made to provide a device to address the above-mentioned problems.
The sash of a half wood half vinyl double hung window found in the prior art, and manufactured by the present Applicant, Kohltech, is comprised of vinyl exterior and wood interior components. The vinyl portion of the sash is designed to seat the glass with an interior wood attachment to hold the insulated glass unit in place; this type of arrangement is referred to as interior glazing. Wood components are attached by silicone and mechanical fasteners. However, it must be noted that removing the glazing stop from this system is not possible without causing irreparable damage to the product. In the event of a seal failure or a broken insulated glass unit, simple replacement is not possible, so a complete sash has to be manufactured and shipped to the customer. An additional deficiency to note is the fact that wood and vinyl have different thermal expansion properties. This results in a product that is more prone to warping and rotting.
U.S. Pat. No. 6,263,626 (Gerhardt) discloses a window or door sash of the type having a sash frame for receiving a transparent sheet, which is retained in the sash frame by a plurality of removably mounted glazing beads. A variety of covering members can be attached to the glazing beads, providing a covering for both the glazing bead and the sash on the interior surface of the window assembly. Typically, the lack of mechanical fasteners in the attachment of the covering to the glazing bead minimizes the effects of differing thermal expansion properties of the materials. However, when the means of attachment includes mechanical fasteners, such as silicone or two sided tape, there is a substantial increase in the difficulty of deglazing the windows. Thus, the Gerhardt design has a direct impact on the glazing of the windows.
U.S. Pat. No. 5,603,585, assigned to the Andersen Corporation, discloses a mortise and tenon joint structure of a vinyl sash. U.S. Pat. No. 5,837,095, also assigned to Andersen Corporation, discloses a welding fixture design that is capable of connecting framing components, such as sash members for a window. In these designs, the interior of the sash has a mortise and tenon joint and the exterior is a 45 degree miter joint. The rails and stiles are milled to shape and to be fusion welded. This provides a continuous vinyl frame with interior mortise and tenon joinery. However, the insulated glass unit (IGU) is welded directly into the sash thus not addressing the deglazing issue. In addition, there is no indication the sash could be comprised of part wood and part vinyl. Thus, the traditional wood look is not achieved. It is an object of the present invention to address the deficiencies found within the prior art.
The present invention overcomes the aforementioned deficiencies by the nature of its design. One embodiment of the present invention will be an exterior glazed vinyl sash with an interior cover that is decorative and adds structural performance characteristics to the product. The sash preferably will be of continuous vinyl composition and fusion welded. The covering can provide an additional continuous weather seal not present in existing half wood, half vinyl designs. The glazing bead is kept free from any covering, which facilitates the deglazing process. Therefore, if the insulated glass unit needs to be replaced, the exterior glazing stop, such as a glazing bead, can be removed, and the glass unit replaced, without impact to the interior finish.
According to an aspect of the present invention, there is provided a fenestration covering to cover the interior surface of a sash, the covering comprises means for attachment to the sash, wherein the covering member is intimately associated with the sash and is dimensioned and adapted to provide a continuous weather seal to a fenestration assembly.
According to another aspect of the present invention, there is provided a fenestration assembly comprising; a sash for retaining a glass unit; glazing beads removably attached on the exterior surface of the sash for securing the glass unit in the sash; a covering member, which is attached to the sash and covers at least the interior surface of the sash, wherein the covering member is intimately associated with the sash and is dimensioned and adapted to provide a continuous weather seal to the fenestration assembly.
According to another aspect of the present invention, there is provided a fenestration covering member comprising a means for attachment to a sash; and a glazing lip terminating at the end of the fenestration covering member which spans the portion of the sash that will be situated on the interior of a building; wherein the cross-section of the fenestration covering member is substantially L-shaped and when installed is in intimate contact with the sash and is dimensioned and adapted to provide a continuous weather seal to a fenestration assembly.
According to another aspect of the present invention, there is provided a fenestration assembly comprising at least one sash for retaining a window pane or glass unit; glazing beads removably attached on the exterior surface of the at least one sash for securing the window pane or glass unit in the at least one sash; and at least one fenestration covering member as defined herein, which is attached to the at least one sash and covers at least an interior surface of the at least one sash; wherein the at least one sash has a corresponding means for attachment to the at least one fenestration covering member to allow for a secure mating engagement; and wherein the at least one fenestration covering member and the at least one sash are made of the same material.
According to an embodiment of the present invention, the covering may have a decorative coating. The decorative coating is present on the covering such that when the covering is properly installed on the sash, the decorative coating faces the interior of a dwelling. Preferably the decorative coating is wood or a wood veneer.
A further embodiment of the present invention provides for at least one T-slot in the covering. Said T-slot will allow for the addition of insulation and/or weather stripping to the covering, promoting the covering from a decorative item to a functional one.
A better understanding of the present invention and its objects and advantages will become apparent to those skilled in this art from the following detailed description, wherein there is described only the preferred embodiment of the invention, simply by way of illustration of the best mode contemplated for carrying out the invention. As will be realized, the invention is capable of modifications in various obvious respects, all without departing from the scope and spirit of the invention. Accordingly, the description should be regarded as illustrative in nature and not as restrictive.
As can be seen from
The covering (1,2) has attachment means to secure it to the sash (3,4). In the embodiment as illustrated, the attachment means are located on the portion of the covering (1,2), which will contact and engage the side of the sash (3,4) opposite the side where the window is secured. In other words, the side of the sash that is likely to abut a window frame. However, the exact location of the attachment means is only limited by the requirement that the corresponding location on the sash (3,4) is capable of receiving the attachment means. Preferably the attachment means take the form of engagement legs (12), however, any alternative form of attachment means, such as snap means or variations of male-female mating means, or any additional type of attachment means known to one of skill in the art for that matter, may be employed while still remaining within the scope of the present invention.
In embodiments where engagement legs (12) are employed by the coverings (1, 2), corresponding receptor channels (11) are prefabricated into the sash (3,4) to allow for mating engagement. Of course, the coverings (1,2) may be designed to fit pre-existing sashes (3,4), and as such, the placement and the nature of the attachment means can vary accordingly, in order to securely attach the covering (1,2) to the desired sash (3,4). For example, the engagement legs (12) may appear at predetermined distances along the length of the coverings (1,2), or alternatively, the engagement legs (12) may take the form of a continuous member which extends out of the coverings (1,2) and spans the entire length of the sash (3,4). The exact nature of the engagement legs (12) is clearly dependent upon the configuration of the corresponding receptor channels (11). Thus, the nature of the receptor channels (11), such as frequency along the length of the sash (3,4), can also vary in a similar and corresponding manner.
An additional point of contact and attachment between the coverings (1,2) and the sash (3,4) is the glazing lip (13). As can be seen from
It is contemplated that the covering (1,2) should contain at least one T-slot (8, 9). The T-slot (8, 9) is effectively a channel or groove which preferably runs the length of the covering (1,2), in the outer portion of the coverings (1,2). The T-slot (8,9) provides the ability to apply additional layers of insulation (14) or weatherstripping to the fenestration. Such additional layers of insulation (14) or weatherstripping may, for example, take the form of weather pile or Q-Lon®, however, any comparable type of insulation and/or weatherstripping (14) known to one of skill in the art may also be utilized. The installation of the insulation and/or weatherstripping is not particularly limiting, and can be carried out according to standard techniques in this field of endeavor, such as applying the insulation and/or weatherstripping (14) to the T-slot (8,9) with an adhesive, or with a mechanical fastener, such as staples. The benefit to this aspect of the invention is that not only will the covering (1,2) provide aesthetic qualities to the interior portion of the sash (3,4), but it will also significantly bolster the insulating capacity of sash (3,4), and in turn, the fenestration assembly as a whole. As indicated above, the covering of the present invention is not merely a cladding, but also can serve as a structural portion of the fenestration, as exemplified by its ability to substantially upgrade the insulating capacity of the fenestration assembly. This particular aspect of the present invention provides the manufacturer with flexibility as to which weather sealing components to use, and thus, desired air and water leakage levels can be obtained and/or manipulated.
The material utilized for the fabrication of the covering (1,2) itself is not particularly limiting, and may be such materials as fiberglass, aluminum, vinyl and various composite materials. Preferably, the material is identical to the material of which the sash (3,4) is fabricated, in order to allow for concomitant thermal expansion of both the sash (3,4) and the covering (1,2) in a harmonious fashion. Finally, it is preferable to color match the covering (1,2) to existing vinyl components from an aesthetic point of view.
As can be seen from the figures, it is preferable that a decorative coating (15) be applied to the face of the covering (1,2). In particular, the decorative coating (15) is applied to the face which is directed toward the interior of a building when said covering (1,2) is properly installed on a fenestration. The decorative coating (15) may also extend to cover the glazing lip (13) such that the entirety of the interior portion of the sash presents the coating (15). It is contemplated that various different decorative coatings (15) can be utilized within the scope of the present invention, such as wood or a wood veneer, paint, vinyl foil or leather. Alternative decorative coatings (15) not explicitly noted may also be utilized, depending on the aesthetic tastes of the end user. Preferably, the decorative coating (15) is wood or a wood veneer. All types of wood that would be considered suitable for this application by one of skill in the art are contemplated within the present invention. However, it is also possible that no decorative coating (15) be applied to the covering (1,2), and thus, the interior finish of the covering (1,2) would be represented by whatever material the covering (1,2) is fabricated therefrom. The glazing lip (13) also allows any decorative coating (15) that may be applied to the covering (1,2) to extend to the, e.g. insulated glass unit (16), thus allowing the interior portion of the sash (3,4) to be covered decoratively in its entirety.
Minor modifications may be effected to the covering (1,2) while still residing within the scope of the present invention. For example, a common sash covering (1) is illustrated in
With reference to the exemplary embodiment illustrated in
In contrast, with reference to the exemplary embodiment illustrated in
Furthermore, the positioning of the meeting rail covering (2) in a double hung window, as exemplified in
The manner in which the decorative coating (15) is applied to the interior face of the covering (1,2) is not particularly limiting. However, as the covering (1,2) itself is able to provide an additional layer of insulation (14) to the fenestration, it is preferred that the means for attaching the decorative coating (15) does not compromise the integrity of the covering (1,2), such as with mechanical fasteners, e.g. nails, screws, staples, etc. Rather, it is preferable that some sort of adhesive is used to attach the decorative coating (15) to the covering (1,2), such as glue, double-sided tape, or any other adhesive appropriate for such an application known to one of skill in the art. This will safeguard against introducing any points of entry for airflow in to the interior of a dwelling.
As previously alluded to, the present invention provides the ability to deglaze and/or replace a damaged window without having to disturb or destroy the covering (1,2) and the decorative coating (15) on the interior of a dwelling. The deglazing can occur from the exterior of the fenestration assembly, such as by removing the glazing beads (17), and the e.g. insulated glass unit (16), can be replaced, and the entire assembly reglazed from the exterior. Thus, although the covering (1,2) and assembly of the present invention provide additional layers of insulation (14) to the fenestration assembly as a whole, it is not directly involved in the glazing process per se. Accordingly, the present invention addresses some of the deficiencies found in the prior art.
An embodiment of the present invention is illustrated in
To install the coverings (1,2) of the present invention, for example, on a window, the coverings (1,2) are cut to length so the rail (19) covers fit the full width of the sash (3), and the stile (20) covers fit the height of the sash (3), minus an appropriate adjustment for the width of both rail (19) covers. Alternatively, the opposite case also holds true, i.e. where the stile (20) covers fit the full height of the sash (3), and the rail (19) covers fit the width of the sash (3), minus an appropriate adjustment for the height of both stile (20) covers. Once the coverings (1,2) are fitted onto the sashes (3), the visual look of the sash (3) as viewed from an interior position will shift from, e.g. a 45 degree mitered joint of the sash (3), as is the standard with most fabricated fenestration sashes (3) to the more traditional wood window look of a mortise and tenon joinery, while concomitantly still providing a 45 degree fusion welded miter on the exterior.
After the sash (3) has been fusion welded, cleaned and glazed, the coverings (1,2) are installed on the main sash (3). When installing a cover, it is critical that the engagement legs (12) are fully engaged in the receptor channels (11), and that the glazing lip (13) is appropriately attached to the sash (3), as in this embodiment of the invention, these are the sole mechanical attachment points between the coverings (1,2) and the sash (3). Once the coverings (1,2) are properly attached, the e.g. weather pile, is inserted in the T-slots and secured in place. The sash (3) is then installed in the frame (18) and tested for fit and function.
The principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2,640,315 | Oct 2008 | CA | national |
