This disclosure relates generally to sliding closures such as windows and more specifically to the preparation and securing of sliding closures for shipment and installation.
Maintaining accurate alignment between the frame and sashes of a window is a major factor in providing a good seal against wind and water between the sashes and the frame, as well as ensuring smooth operation of slidable sashes. Alignment of the window unit sashes, frame, and other members relative to one another is best done during factory assembly of the window unit. However, it has proven difficult, and often economically unfeasible, to maintain proper alignment of the unit during transport and possibly warehousing and retail display of the window units, without taking special, possibly expensive and inconvenient measures. Similar considerations also apply to sliding doors and gliding windows.
Misalignment can take several forms. Jambs may become warped or bent outwards, due, for example, to the outward pressure of seals and weather stripping between the sashes and the jambs. Window units may be improperly stacked at some point in the transportation process, allowing the weight of the sashes to cause excessive compression of the seals or weather stripping, to the point of creep, thereby causing poor sealing when the sashes are returned to their proper position. Various bumping and dropping of the window units may cause the corner angles of frames to deviate significantly from their intended values, typically 90°, a phenomenon known as racking.
While robust packaging can improve the chances of window units arriving at the construction site in an aligned condition, such packaging can become expensive, and there is still the possibility that misalignment will occur after removal of the packaging, but prior to installation.
There is therefore a need to preserve the alignment of sliding closures such as windows provided at the factory throughout the transportation, sale, and installation, without adding excessive cost and without complicating the installation process.
A shipping and installation fixture is provided that includes a pair of packaging clips located between the jambs and a sliding sash of a window unit, wherein the clips are attached to the jambs. During shipping and installation, the clips maintain a predetermined spacing between the sash and the jambs. The clips also include coupling brackets for connecting a tensioned coupling member such as a length of packaging strap between the clips. The tension of the coupling member urges the clips toward one another, thereby urging them into contact with the sides of the sash, thus reducing outward bowing of the jambs to which the clips are attached and frictionally coupling the sash to the jambs, thereby reducing the tendency of the frame to undergo racking. The clips also serve to reduce the risk of lock damage due to deformation of the window during shipping. Once installed at the factory, the fixture can remain on the window unit until installation in a rough opening of a building is complete; thereby further preserving the alignment provided at the factory. The fixture can be used with window units having either vertically sliding panels or horizontally sliding panels. The fixture can also be used with sliding doors.
The components of the following figures are illustrated to emphasize the general principles of the present disclosure and are not necessarily drawn to scale. Reference characters designating corresponding components are repeated as necessary throughout the figures for the sake of consistency and clarity.
The present disclosure is directed to a packaging system for use in conjunction with sliding closures, such as triple hung windows, double hung windows 102 (
An aspect of the disclosure is the use of a packaging system to improve the shipping and installation of windows. Another aspect of the disclosure is a method of applying a packaging system to a window. A further aspect of the disclosure is a system that holds a window or door square during installation but does not interfere with the installation process. These and other aspects will emerge through this detailed description.
A desired clearance 107 exists between the jambs of the window frame 103 and the lower sash 104. The desired clearance is a spacing that ensures smooth sliding operation of the lower sash 104 while at the same time maintaining proper engagement with and compression of weather stripping between the sash and the jambs to inhibit drafts and leakage. Clips 10, 10′ are disposed at the upper corners of the lower sash; i.e. at the ends of the check rail 108 of the sash, according to one embodiment of the invention. Each clip has a tab or tabs 16 that project downwardly between the sash and the adjacent jamb and the tabs have a thickness generally equal to the desired clearance 107. A base 12 of each clip rests atop the check rail 108 of the lower sash and a retainer 7 of the clip projects upwardly therefrom. A rear insert 26 of each clip (not visible in
A coupling member 116 in the form of a strap or band in the illustrated embodiment has end portions disposed within slots 38 in the clips 10, 10′ and the coupling member 116 extends between the two clips. The coupling member 116 is secured to the clips and thereby to the jambs by the screws 112. More specifically, the screws 112 extend through the upper openings 50, through the ends of the coupling member 116 disposed therein, and are threaded into the adjacent jamb of the frame. This closes the slots 38 through which the ends of the coupling member 116 extends to clamp the ends of the coupling member 116 within the clips. The coupling member 116 is sufficiently taught to hold the jambs of the window frame against the tabs 16 of the clips 10, 10′, which keeps the jambs straight, prevents them from bowing outward, maintains the preferred clearance gap between the sash and the jambs, and holds the frame in this configuration during shipment and during installation.
At the manufacturing facility, a window or door unit is prepared for the packaging and installation system of this invention. The sliding sash is shut and the clips may be inserted at the ends of the check rail of the sliding sash as described. The window unit may then be mechanically clamped in a fixture that holds the sashes straight and the frame square. With the frame straight and square, the coupling member 116 may be installed by sliding one end portion into the slot 38 of either the clip 10 on the right side of the window frame 103 or the clip 10′ on the left side of the window frame 103. A right handed installer, for example, may prefer to start by sliding an end of the coupling member into the slot of the clip on the left side of the window frame 103. It is preferred that an edge of the coupling member 116 be slid completely into the slot so that the edge of the coupling member engages the bottom of the slot. This ensures that when a fastener is installed, the fastener will pierce and secure the coupling member 116 in the proper position within the slot.
With the coupling member 116 properly positioned, a fastener, preferably a screw, is extended through the upper fastener passage 50 and through approximately the center of the coupling member 116. The screw is then driven into the window frame 103, thereby securing the packaging clip 10 in a fixed position and locking the end portion of the coupling member 116 into its slot. The fastener 112 should be snug but without crushing or breaking the packaging clip, and should be of a sufficient length so that it does not pierce the outside face of the jamb. Tightening the fastener 112 causes the slot 38 to close and clamp onto the end portion of the coupling member thereby locking the end portion of the coupling member to the clip. If the window 102 is a larger window unit, or the upper and lower sashes 104, 106 are larger or heavier, it may be desirable to drive a fastener through the lower fastener passage 52 and into the frame for added security. The first packaging clip 10 is now securely installed and the end portion of the coupling member 116 is locked therein.
The coupling member 116 is then extended across the window frame 103 from packaging clip 10 to packaging clip 10′ (or vice versa), pulled taught, and secured to packaging clip 10′ in the same manner to form the packaging system 100. With the packaging system 100 installed, the window unit may be removed from the clamping fixture. The packaging system insures that the window frame 103 will remain square, straight, and secure during shipment and will maintain this configuration during installation. Furthermore, since the coupling member 116 does not wrap around the outsides of the jambs, it does not interfere with shimming or with the mulling process during installation or when individual window units are joined to form compound window units in the field. Thus, window units can be positioned in a roughed-in opening, shimmed plumb and square, and secured with fasteners through its nailing flange or brick mould to the framing members surrounding the opening, all the while being retained square and straight by the packaging and installation system disclosed herein.
After a window unit is installed in a roughed-in opening as described, the clips 10 and coupling member 116 can be removed by removing the screws, cutting the coupling member, or otherwise removing the packaging system. Afterward, it is preferred that the screws removed from the clips be driven back into their original holes to seal any moisture passageways that may have been formed by the holes. Thus, the system holds the window straight and square during installation and maintains the proper clearance gap between the jambs and sashes to insure the proper sliding operation of the sash while simultaneously maintaining proper contact between the sash and weather stripping to prevent drafts and leaks. Once affixed within the opening, these characteristics are preserved in the installed window.
Reference will now be made to
A pair of struts 23 extends upward from the base 12 and form a portion of a frame of the packaging clip 10. The struts 23 function to strengthen the packaging clip 10 by at least increasing a bending stiffness in the horizontal direction 8, and also facilitate fabrication of the component 10. The struts 23 are illustrated as generally triangular in shape but may be any shape and thickness necessary to increase the strength of the frame. Furthermore, the struts 23 may facilitate fabrication of the packaging clip 10 in that they provide features that may improve removal of a molded clip from a mold during an injection molding process. The struts 23 may taper near an upper portion 17 of the packaging clip 10.
A pair of spacer tabs 16 extends or depends vertically downward below the base lower surface 14 and form a portion of the rear surface 20. As perhaps most clearly seen in
The packaging clip includes at least one fastener passage and in the embodiment illustrated, the packaging clip 10 includes two fastener passages, an upper fastener passage 50 and a lower fastener passage 52. The upper fastener passage 50 and lower fastener passage 52 extend from a front 19 of the packaging clip 10 toward the rear surface 20 and through the rear insert 26 generally in the horizontal direction 8. The upper fastener passage 50 and lower fastener passage 52 provide a passageway for a respective fastener to extend from the front 19 of the packaging clip 10 and exit through a rear edge of the rear insert 20 and into the window frame to secure the packaging clip 10 in place. The upper fastener passage 50 may be the primary fastener passage and may receive a single fastener for use with all window sizes. For larger window frames, both the upper fastener passage 50 and lower fastener passage 52 may each receive a fastener for a stronger hold.
A fastener, generally a screw, may extend from the front of the package clip 10, through a fastener passage (either the upper fastener passage 50, the lower fastener passage 52, or both the upper fastener passage 50 and the lower fastener passage 52) and exit the packaging clip 10 to be driven into a window frame. The fastener functions to anchor the packaging clip 10 in the installed position to the window frame when the fastener is inserted through the respective fastener passage and driven into the window frame. Each fastener may have a fastener head and when the fastener is installed, the fastener head may rest against an upper rim 51, for example, if the fastener is installed in the upper fastener passage 50, or a lower rim 53, for example, if the fastener is installed in the lower fastener passage 52. With the fastener head abutting the rim (either the upper rim 51 or the lower rim 53), the packaging clip 10 remains in the proper position relative to the window frame.
An upper fastener passage protrusion 54 and a lower fastener passage protrusion 56 each extend from the front 19 of the packaging clip 10. The upper fastener passage 50 has a plurality of ribs 24 that extend from the upper fastener passage protrusion 54 and interface with the front 19. The ribs 24 at least function to strengthen the packaging clip 10, in particular, near the upper fastener passage 50. A plurality of casting or molding features 58 extend from the lower fastener passage protrusion 56. The casting features 58 primarily aid in the fabrication of the packaging clip 10 but may also strengthen the packaging clip 10 near the lower fastener passage protrusion 56.
The upper fastener passage 50 is about parallel with the base lower surface 14 of the packaging clip 10 and extends in the horizontal direction 8. Thus, a fastener inserted through the upper fastener passage 50 will be about parallel with the base lower surface 14 of the packaging clip 10. Referring to
The rear insert 26 of the packaging clip 10 is comprised of a plurality of webs 28, a rear upper fastener protrusion 30, a rear lower fastener protrusion 34 and a lower insert portion 32. The webs 28 extend between the rear upper fastener protrusion 30 and the rear lower fastener protrusion 34, as well as from the rear upper fastener protrusion 30 to a top end 29 of the packaging clip 10. The webs 28 form a portion of the frame of the packaging clip 10 and at least function to strengthen the packaging clip 10. As illustrated, the rear lower fastener protrusion 34 is integral with the lower insert portion 32 and has a lower insert portion width 33. The rear upper fastener protrusion 30 may have a width substantially the same as the lower insert portion width 33. The lower insert portion 33 is about the same (or slightly less) width as the width of a jamb track channel on the window frame that the rear insert 26 is disposed within when installed. It is useful to provide a clearance between the rear insert 26 and channel 114 to accommodate any expansion of either the rear upper fastener protrusion 30 or the rear lower fastener protrusion 34 that may occur when a fastener is installed and tightened in either passage 50, 52. Since the width 33 of the lower insert portion 32 and the width of the rear upper fastener protrusion 30 are about the width of the channel, the packaging clip 10 may be more firmly held when the rear insert 26 is disposed within the channel. When installed, the rear insert 26 may be within the jamb track channel 114 and the rear surface 20 of the packaging clip 10 may rest against the window jamb on either side of the jamb track channel.
A slot 38 is formed toward the top end 29 of retainer 7 and extends in the vertical direction 9. With reference to
The packaging clip 10 may be made from any suitable material. Preferably, the packaging clip is made from a plastic or polymer material that may be injection molded. The packaging clip may be fabricated from a metal or alloy as well. However, it is preferred that the packaging clip be produced from a polymer.
Alternative embodiments are also possible. For example, coupling member 116 may be a strap as illustrated or a string, cable, wire, or other long thin member, with appropriate fastening and tensioning devices in the packaging clips, coupling member 116 may also be a variable length coupling member, such a strap, string, or other like member looped around a coupling portion of each packaging clip and attached to itself in an adjustable overlapping manner. Elastically extensible flexible members of the general type known as bungee cords may also be used. In yet other embodiments, the coupling member may be in two parts, with each part attached to a packaging clip, with the two parts being connected by a tensioning device, such as a spring or toggling lever device, as would be apparent to one skilled in the art. While it is convenient for coupling member 116 to be a flexible material, non-flexible coupling members are also contemplated. For example, the coupling member could be made up of a first connecting part hingedly coupled to the first clip and a second connecting part hingedly coupled to the second clip, wherein the first and second connecting parts overlap and are clamped or otherwise attached to one another. Alternative configurations for the coupling members will be apparent to one skilled in the art.
Attachment of the coupling member to the packaging clips need not involve the screw holding the clips to the jamb, but could involve other fastening means, such as wedging or jamming devices on the clips, or looping around a post on the clip and attaching a portion of the coupling member to itself. Other coupling member configurations and attachment methods will be apparent to one skilled in the art, and are considered to be within the scope of the invention. Likewise, some jambs may include features that allow the packaging clips to be attached to them without the need for screws threading into the jamb.
Of course, if the sliding closure is a window as in the preferred embodiment described above, the clips are attached to the side frame members or jambs of the window frame. However, if the sliding closure is a gliding window or a sliding door 202, as shown in
The invention has been described above within the context of a preferred exemplary embodiment considered by the inventors to be the best mode of carrying out the invention. It will be apparent to those skilled in the art; however, that various additions, deletions, and modifications of the above described embodiment, both subtle and gross, can be made without departing from the spirit or scope of the invention. For example, the particulars of the clip of the illustrated embodiment are not limiting and a wide variety of shapes, features, and configurations of a clip may be developed by the skilled artisan so long as the clip performs the functions ascribed to the illustrated embodiment. The ends of the coupling member may be secured to the clip in ways other than being captured within a slot such as, for instance, by being wrapped around a feature of the clip or simply screwed to the surface of the clip. These and many other revisions are possible within the scope of the invention, which is delimited only by the claims.
Priority is hereby claimed to the filing date of U.S. provisional patent application No. 61/440,447 filed on 8 Feb. 2011.
Number | Name | Date | Kind |
---|---|---|---|
2728117 | Zappone et al. | Dec 1955 | A |
2929495 | Simonsen | Mar 1960 | A |
3205982 | Chimienti | Sep 1965 | A |
3253704 | Hillier | May 1966 | A |
3584416 | Baumgartel | Jun 1971 | A |
3643377 | Anderson | Feb 1972 | A |
4691477 | Governale | Sep 1987 | A |
4920713 | Borresen et al. | May 1990 | A |
5209017 | Ridge | May 1993 | A |
5239780 | Mott et al. | Aug 1993 | A |
5365697 | Vanderpan | Nov 1994 | A |
5655332 | Papadopoulos | Aug 1997 | A |
6161605 | Pena | Dec 2000 | A |
6725604 | Vanderpan | Apr 2004 | B1 |
7100329 | Pleasants | Sep 2006 | B2 |
7581352 | Klingbyle | Sep 2009 | B2 |
7681360 | Daniels et al. | Mar 2010 | B2 |
7716886 | Gordon | May 2010 | B2 |
7757365 | Ouellette | Jul 2010 | B2 |
7856760 | Klingbyle | Dec 2010 | B2 |
8322079 | Daniels et al. | Dec 2012 | B2 |
8333359 | Gordon | Dec 2012 | B2 |
20030005641 | Eakes et al. | Jan 2003 | A1 |
20040060241 | Staples et al. | Apr 2004 | A1 |
Number | Date | Country | |
---|---|---|---|
20120198771 A1 | Aug 2012 | US |
Number | Date | Country | |
---|---|---|---|
61440447 | Feb 2011 | US |