BACKGROUND OF THE INVENTION
The present invention relate generally to fenestration assemblies and in particular to a system and method for field mulling of windows and doors.
Window and door units are sometimes grouped together and installed into one opening in the building that must first be connected together and sealed. This connection of units is called mulling. Units can be mulled in the factory (Factory Mulled) or on the jobsite prior to installation (Field Mulled). Factory mulled windows are typically preferred. Field mulling is used when factory mulling cannot be performed due to size, weight or shipping limits. Field mulling adds labor and complexity because the installer must assemble and seal the unit prior to installation. Once mulled on the jobsite the oversized units must be lifted into the opening which risks injury to the installers as well as damage to the mulled unit.
It would be desirable to provide a system and method for field mulling two or more fenestration assemblies (e.g., windows and/or doors) that allows each fenestration assembly to be installed in an opening of a building one at a time.
SUMMARY OF THE INVENTION
In accordance with an embodiment, a system for field mulling a plurality of fenestration assemblies in an opening includes a first fenestration assembly positioned in the opening, the first fenestration assembly comprising a mull halve a second fenestration assembly positioned in the opening adjacent to the first fenestration assembly, the second fenestration assembly having a mull halve and positioned so that the second fenestration assembly mull halve is adjacent to the first fenestration assembly mull halve and at least one H-shaped mull connector coupled to the first fenestration assembly mull halve and the second fenestration assembly mull halve
In accordance with another embodiment, a mulling assembly for field mulling a plurality of fenestration assemblies in an opening includes a first mull halve having an interior side and an exterior side, a second mull halve having an interior side and an exterior side, a first mull connector coupled to the interior side of the first mull halve and the interior side of the second mull halve, the first mull connector having an H-shape and a second mull connector coupled to the exterior side of the first mull halve and the exterior side of the second mull halve, the second mull connector having an H-shape.
In accordance with another embodiment, a mulling assembly for field mulling a plurality of fenestration assemblies in an opening includes a first mull halve having an interior side and an exterior side, the first mull halve comprising a hook-shaped connector on the exterior side, a second mull halve having an interior side and an exterior side, the second mull halve comprising a tab on the exterior side, wherein the tab is configured to be received by the hook-shaped connector of the first mull halve to join the first mull halve and the second mull halve and a first mull connector coupled to the interior side of the first mull halve and the interior side of the second mull halve, the first mull connector having an H-shape.
In accordance with another embodiment, a method for field mulling a plurality of fenestration assemblies on an opening includes positioning a first fenestration assembly in the opening, the first fenestration assembly having a mull halve, connecting the first fenestration assembly to a frame of the opening, positioning a second fenestration assembly in the opening adjacent to the first fenestration assembly, the second fenestration assembly having a mull halve and wherein the second fenestration assembly is positioned so that the second fenestration assembly mull halve is adjacent to the first fenestration assembly mull halve, connecting the second fenestration assembly to the frame of the opening and connecting the first fenestration assembly mull halve to the second fenestration assembly mull halve using at least one H-shaped connector.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a building wall frame and multiple fenestration assemblies in accordance with an embodiment;
FIG. 2 is a perspective view of a window with a mull halve in accordance with an embodiment;
FIG. 3 is a perspective view of a window and a pair of mull halves in accordance with an embodiment;
FIG. 4 illustrates a method for field mulling two or more fenestration assemblies in accordance with an embodiment;
FIG. 5 is a perspective view of a wall frame with a first window installed in accordance with an embodiment;
FIG. 6 is a view of a lower mull bracket of FIG. 5 attached to a sill of a wall frame in accordance with an embodiment;
FIG. 7 is a view of an upper mull bracket of FIG. 5 attached to a header of a wall frame in accordance with an embodiment;
FIG. 8 is a view of a mull halve and an upper mull bracket in accordance with an embodiment;
FIG. 9 is a perspective view of a wall frame with two windows installed in accordance with an embodiment;
FIG. 10 is a perspective view of components of a mull assembly in accordance with an embodiment;
FIG. 11 is a top view of two mull halves in accordance with an embodiment;
FIG. 12 is a top view of two mull halves in accordance with an embodiment;
FIG. 13 is a top view of components of a mull assembly in accordance with an embodiment;
FIG. 14 is a top view of a completed mull assembly in accordance with an embodiment;
FIG. 15 is a top view of components of a mull assembly in accordance with an embodiment;
FIG. 16 is a top view of two mull halves in accordance with an embodiment;
FIG. 17 is a top view of two mull halves in accordance with an embodiment;
FIG. 18 is a top view of components of a mull assembly in accordance with an embodiment;
FIG. 19 is a top view of a completed mull assembly in accordance with an embodiment;
FIG. 20 is a perspective view of a completed mulled window in accordance with an embodiment;
FIG. 21 is a perspective view of a window with a mull halve in accordance with an embodiment;
FIG. 22 is a perspective view of a window and a pair of mull halves in accordance with an embodiment;
FIG. 23 is a view of straps attached to a jamb and sill of a wall frame in accordance with an embodiment; and
FIG. 24 is a view of straps attached to a jamb and header of a wall frame in accordance with an embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description discusses a system and method for field mulling two or more fenestration assemblies (e.g., windows and/or doors). While the following description refers to windows, it should be understood that the systems and methods described herein may also be used with other types of fenestration assemblies (e.g., doors). For the purposes of this application, the term “exterior” will refer to the direction toward the outside of an enclosure or building while the term “interior” will refer to the direction toward the inside of the enclosure or building.
FIG. 1 is a perspective view of a building wall frame and multiple fenestration assemblies in accordance with an embodiment. The building (or other enclosure) wall frame 12 includes an opening 14 defined by a header 16, a sill 18 and jambs 28 and 30. Wall frame 12 also includes a top plate 20, a bottom plate 22 and studs 32. The opening 14 is designed to receive multiple windows. In FIG. 1, a first window 34, a second window 36 and a third window 38 may be installed in the opening 14 of wall frame 12 and mulled together within the opening using the systems and methods described herein. Wall frame 12 and windows 34, 36, 28 have an exterior side 24 and an interior side 26. It should be understood the field mulling systems and method described herein may be used with other types of windows than shown in FIGS. 1-20, such as, for example, casement, single hung, double hung, horizontal sliding windows or any other operating style of window. It should also be noted that a structure with three separate fenestration assemblies (e.g., windows 34, 36, 38) is exemplary and that in various embodiments two or more separate fenestration assemblies may be used. The two or more fenestration assemblies are designed to be installed in an opening side-by-side as illustrated by item 40.
A mull assembly is provided to facilitate the mulling of the first window 34 and the second window 36 and the mulling of the second window 36 and the third window 38. FIG. 2 is a perspective view of a window with a mull halve in accordance with an embodiment. Window 50 (e.g., first window 34, second window 36 or third window 38) includes a frame 52 with rails 56 and stiles 58. A glazing 54 is housed within the frame 52. A first side 68 of frame 52 is perpendicular to an exterior side 24 and an interior side 26 of the frame 52. A second side 70 of frame 52 is perpendicular to the exterior side 24 and the interior side 26 of the frame 52 and parallel to the first side 68 of the frame 52. A mull halve 60 is attached to the first side 68. In one embodiment, the mull halve is secured to the window 50 prior to the window 50 being installed in an opening. Mull halve 60 is used for field mulling of the window 50 with another window in an opening 14 (shown in FIG. 1). An upper mull bracket 64 and a lower mull bracket 66 are attached to mull halve 60 and used to secure the frame 52 to a wall frame 12 (shown in FIG. 1)
When a window will be connected with two other windows, the window 50 may also include a second mull halve 62 attached to the second side 72 of the frame 52 as shown in FIG. 3. Mull halve 60 and mull halve 62 are designed to cooperate or interconnect with a mull halve on another window to secure the windows together. Each mull halve 60, 62 may be attached to the frame 52 using mechanical fasteners, for example, screws. For example, in FIG. 3, mull halve 60 may be secured to frame 52 using mechanical fasteners 76. The upper mull bracket 64 may be attached to the frame 52 and mull halve 60 using mechanical fasteners 72. The lower mull bracket 66 may be attached to the frame 52 and mull halve 60 using mechanical fasteners 74.
Two or more windows 50 with a mulling assembly as described herein may be field mulled as described further below with respect to FIGS. 4-20. FIG. 4 illustrates a method for field mulling two or more fenestration assemblies in accordance with an embodiment. At block 402, a first window is placed in an opening, for example, an opening 14 (shown in FIG. 1) in a building wall frame. FIG. 5 is a perspective view of a wall frame with a first window installed in accordance with an embodiment. In FIG. 5, the first window 34 is placed in the opening 14 of wall frame 12 in the direction as shown by arrow 80. The first window may be made plumb, level and square with shims. At block 404 of FIG. 4, the first window 34 is attached to the frame of the opening. For example, the first window 34 may be attached to frame 12 using a nailing fin (not shown). In an embodiment, the frame 52 may include a groove or kerf (not shown) that is used to connect the nailing fin to the frame 52. In addition, the upper mull bracket 64 and lower mull bracket 66 are attached to the wall frame 12 as shown in FIGS. 5-7. In particular, the lower mull bracket 66 may be attached to the sill 18 of the wall frame 12 using mechanical fasteners 77 as shown in FIG. 6. The upper mull bracket 64 may be attached to the header 16 of wall frame 12 using mechanical fasteners 78 as shown in FIG. 7. As mentioned, the upper mull bracket 64 and the lower mull bracket 66 are also attached to the mull halve 60 which is attached to a first side 68 of the window 34. FIG. 8 is a view of a mull halve 60 and an upper mull bracket 64 in accordance with an embodiment. FIG. 8 shows one embodiment of a mull halve 60 structure. Mull halve 60 is designed to cooperate with a mull halve on a second window to facilitate mulling of the first window and the second window as described further below.
Returning to FIG. 4, at block 406 a second window is placed in the opening. FIG. 9 is a perspective view of a wall frame with two windows installed in accordance with an embodiment. In FIG. 9, the second window 36 is placed in the opening 14 of wall frame 12 in the direction as shown by arrow 82. The second window 36 is positioned adjacent to the first window 34. The second window may be made plumb, level and square with shims. At block 408 of FIG. 4, the second window 36 is attached to the frame of the opening. For example, the second window 36 may be attached to frame 12 using a nailing fin (not shown). In an embodiment, the frame 52 may include a groove or kerf (not shown) that is used to connect the nailing fin to the frame 52. In addition, the upper mull bracket 64 and lower mull bracket 66 on a first side 90 of the second window 36 may be attached to the wall frame 12 as discussed above with respect to FIGS. 6 and 7.
Referring again to FIG. 4, at block 410 the mull halve on the first side 68 (shown in FIG. 5) of the first window 34 and the mull halve on the second side 92 (shown in FIG. 9) of the second window 36 are attached or secured together. FIG. 10 is a perspective view of components of a mull assembly in accordance with an embodiment and FIG. 13 is a top view of components of a mull assembly in accordance with an embodiment. In FIGS. 10 and 13, the mull assembly components consist of a mull halve 60 on the first side 68 of a first window 34 and a mull halve 98 on a second side 92 of a second window 36. On the interior side 26, a mull connector 100, a trim connector 102 and an interior trim 104 are used to secure together the mull halves 60, 98. On the exterior side 24, a sealing connector 106 and exterior trim 108 are used to secure together the mull halves 60, 98.
As mentioned, the mull halves on each window are designed to cooperate or interconnect. FIG. 11 is a top view of two mull halves in accordance with an embodiment. In FIG. 11, a mull halve 60 on the first window includes a tab 116 on the interior side 26 of the mull halve and a mull halve 98 on the second window includes a tab 118 on the interior side 26 of the mull halve. Mull halve 60 includes a hook-shaped connector 110 on an exterior side of the mull halve and mull halve 98 includes a tab or extension 112 on the exterior side of the mull halve. The tab 112 is designed to be positioned or received in the hook shaped-connector 110 as indicated by arrow 114. Tab 116 and tab 118 are designed to be positioned adjacent to one another as indicated by arrow 120. FIG. 12 shows the two mull halves 60 and 98 after they are positioned next to each other. Tab 112 is positioned in hook-shaped connector 112 to secure the exterior side of the mull halves 60, 98. Tab 116 and 118 are adjacent one another. A mull connector 100 is used to join the tabs 116, 118 on the interior side as shown in FIGS. 13 and 14. Mull connector 100 has a U-shape. In an alternative embodiment, as shown in FIG. 15, the mull connector 100 used to join tab 116 and tab 118 of mull halves 60 and 98, respectively, is an H-shaped connector.
In another embodiment, each mull halve may have tabs on the interior and exterior sides and the mull assembly includes two-H-shaped connectors as shown in FIGS. 16-19. FIG. 16 is a top view of two mull halves in accordance with an embodiment. In FIG. 16, a mull halve 130 on a first window includes a tab 136 on the interior side of the mull halve and a mull halve 132 on a second window includes a tab 134 on the interior side of the mull halve. Mull halve 130 includes a tab 140 on an exterior side of the mull halve and mull halve 132 includes a tab 138 on the exterior side of the mull halve. Tab 134 and tab 136 are designed to be positioned adjacent to one another when the two mull halves 130, 132 are brought together as indicated by arrows 180 and 182. Tab 138 and tab 140 are designed to be positioned adjacent to one another when the two mull halves 130, 132 are brought together as indicated by arrows 180 and 182. FIG. 17 shows the two mull halves 60 and 98 after they are positioned next to each other. Tabs 134 and 136 are positioned adjacent one another and tabs 138 and 140 are positioned adjacent to one another.
FIG. 18 is a top view of components of a mull assembly in accordance with an embodiment. The mull assembly components consist of a mull halve 130 on the first side of a first window and a mull halve 132 on a second side of a second window. On the interior side 26, a mull connector 150, a trim connector 152 and an interior trim 154 are used to secure together the mull halves 130, 132. On the exterior side 24, a mull connector 160, a sealing connector 156 and exterior trim 158 are used to secure together the mull halves 130, 132. The mull connector 150 is used to join the tabs 138, 140 on the interior side as shown in FIGS. 18 and 19. The mull connector 150 is an H-shaped connector. The mull connector 160 is used to join the tabs 134, 136 on the exterior side as shown in FIGS. 18 and 19. The mull connector 160 is an H-shaped connector.
Returning to FIG. 4, at block 412 a third window 38 is placed in the opening 14 of the wall frame 12 as shown in FIG. 20. The third window 38 is installed adjacent to the second window 36 with the mull halves of the second window 36 and third window 38 interconnected. The third window 38 may be made plumb, level and square with shims. At block 414 of FIG. 4, the third window 38 is attached to the frame 12 of the opening 14. For example, the third window 38 may be attached to frame 12 using a nailing fin (not shown). In an embodiment, the frame 52 may include a groove or kerf (not shown) that is used to connect the nailing fin to the frame 52. In addition, the upper mull bracket 64 and lower mull bracket 66 are attached to the wall frame 12 as discussed above with respect to FIGS. 6 and 7.
At block 416 of FIG. 4, the mull halve on the first side 90 (shown in FIG. 9) of the second window 36 and the mull halve on a first side 174 (shown in FIG. 20) of the third window 38 are attached. As described above with respect to FIGS. 11-19, the mull halves are designed to cooperate or interconnect. In one embodiment as shown in FIGS. 11-15, the mull halves 60, 98 include tabs 116, 118 on an interior side 26 and a hook-shaped connector 110 and tab 112 on the exterior side 24 of the mull halves. A mull connector 100 is used to join the tabs 116, 118 on the interior side. The mull connector 100 may be, for example, a U-shaped connector or an H-shaped connector. On the exterior side 24, tab 112 is positioned in the hook-shaped connector 110. In another embodiment as shown in FIGS. 16-19, the mull halves 130, 132 include tabs 138, 140 on an interior side 26 and tabs 134, 136 on an exterior side 24. An H-shaped mull connector 150 is used on the interior side 26 to secure tabs 138, 140 together. An H-shaped mull connector 160 is used on the exterior side 24 to secure tabs 134, 136 together.
Returning to FIG. 4, at block 418, the mull between the first window 34 and the second window 36 and the mull between the second window 36 and third window 38 are sealed. As shown in FIGS. 13, 14, 15, 18 and 19 a sealing connector 106, 156 is positioned external to the mull connector on the exterior side 24 of each mull. In an embodiment, a sealing block (not shown) may be filled with silicone caulking to complete the sealing of the mulls. At block 420 of FIG. 4, trim connectors are attached to the mulls as shown in FIGS. 13, 14, 15, 18 and 19. A trim connector 102, 152 is positioned external to the mull connector 100, 150 on an interior side 26. At block 422, trim is attached to the interior side 26 and exterior side 24 to complete the mull assembly. As shown in FIGS. 13, 14, 15, 18 and 19, the exterior trim 108, 158 is positioned external to the sealing connector 106, 156 on the external side 24 and the interior trim 104, 154 is attached external to the trim connector 102, 152 on the interior side 26. FIGS. 14 and 19 show competed mull assemblies in accordance with various embodiments. FIG. 20 shows a completed mulled window 170. In FIG. 20, a first window 34, a second window 36 and a third window 38 are installed and field mulled in the opening 14 of the wall frame 12.
As discussed above with respect to FIGS. 2, 3, 4, 6 and 7, an upper mull bracket 64 and a lower mull bracket 66 may be used to attach a window (e.g., first window 34, second window 36, third window 38) to a wall frame 12. In an alternative embodiment, a set of straps may be used to connect the window to the wall frame 12. The straps may be connected to the window on the sides of the window frame that do not have a mull halve. FIG. 21 is a perspective view of a window with a mull halve in accordance with an embodiment. In this embodiment, straps 86 are attached to the upper and lower rails 56 and to the stile 58 on the second side 70 of the window 50. A mull halve 60 is attached to a first side 68 of the window frame 62, In FIG. 21, three straps 86 are positioned on each of the upper and lower rails 56 and three straps 86 are positioned on the stile 58, however, in various embodiments, a different number of straps 86 may be used. For a window that has two mull halves, such as the window shown in FIG. 3, the straps 86 may be attached to the upper and lower rails 56 as shown in FIG. 22. In FIG. 22, a mull halve 60 is attached to a first side 68 of the window 50 and a mull halve 62 is attached to a second side 70 of the window 50.
The straps 86 may be attached to the window frame 52 using mechanical fasteners, such as, for example, screws, In addition, the straps may be attached to the wall frame 12 using mechanical fasteners as shown in FIGS. 23 and 24. In FIG. 23, straps 86 are shown attached to a jamb 28 and a sill 18. For example, a strap 86 is connected to the sill 18 using a mechanical fastener 88. If the depth of the wall frame provides sufficient space, the strap 86 may be connected to the wall frame in a flat configuration as shown in FIG. 23. If, however, the depth of the wall frame does not have sufficient space, the straps 86 may be bent to attach to the wall frame as shown in FIG. 24. In FIG. 24, straps 86 are shown attached to a jamb 28 and a header 16. For example, a strap 86 is connected to the header 16 using a mechanical fastener 88. The straps 86 may be constructed from a metal, for example, galvanized steel.
It is important to note that the construction and arrangement of system for field mulling of a plurality of fenestration assemblies as described herein is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, elements shown as integrally formed may be constructed of multiple parts or elements and vice versa, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present inventions as expressed in the appended claims.
Patent Application
20150020465
