The present invention relates generally to frame assemblies carrying films. More particularly, it relates to apparatus, methods, and a kit for easily and reliably assembling window film frame assemblies carrying window films in a manner for avoiding formation of permanent film flows in the films that diminish their optical properties, while at the same time providing for thermal insulation of window assemblies during repeated heating seasons.
Window films are generally transparent plastic and/or metallized laminates that are applied as a thin layer to transparent panels, such as glass windows. Window films are available in many different compositions for bringing about varying effects on the optical and mechanical properties of the underlying transparent panels. Window films can reduce energy costs by minimizing the amount of heat entering a building through sunlight, thereby decreasing the amount of energy needed to cool the building. Window films also act as a filter for reflecting most ultraviolet and infrared wavelengths while allowing passage of visible light. This can result in substantial reductions in cooling costs. As noted, such films reduce the amount of ultraviolet entering a window, and are also often applied to reduce fading of the contents of a room. Other kinds of thin window films include security films that are applied to prevent glass from shattering, as well as privacy films for controlling the visible light transmitted for effecting privacy purposes.
It will be appreciated that several factors are considered in selecting the correct film to be installed. Such factors include visible light transmission, properties of solar energy to be reflected, and aesthetic considerations, such as distortion free viewing following installation.
Because window films are usually installed by applying them to either or both surfaces of flat finished glass, the resulting laminates are less costly than buying chemically altered specialty glass for bringing about the same desired solutions. Because window films provide energy savings and help protect furnishings among other advantages, they are generally considered to be an investment that pays for itself. As such, they have gained widespread commercial acceptance.
Attempts have been made to space transparent films incrementally from windows in order to improve the R-value associated with the windows. An R-value is a rating used to measure how well insulation can resist heat flow. The higher the R-value, the greater the insulating properties and the slower heat and cold flows through it. However, while window films are beneficial they have not necessarily been successfully adapted for use in installation over transparent panels, such as windows. In part, this is due to the films being very thin, such as in the order of about 2 mil. Typically, when applied to a frame for mounting the same, they cannot be kept planar over a frame opening. This is due primarily to their flimsy nature (i.e., they cannot sustain their dimensions). Accordingly, physical distortions of the films may arise and their optical properties are compromised. Because these films tend to be heat shrinkable, one typical approach for addressing their flimsy nature is to apply heat locally on the film. This is usually done with a hair dryer, heat gun, or other similar device. Heating causes the film to shrink over the frame opening, whereby it assumes a taught and generally planar orientation. As such, visual distortions are minimized. However, when heat is applied, it is usually done after the film has been applied to the frame and the film has reached room temperature of its operating environment. In some cases, heat is applied up to 24 hours after the film has been mounted on a frame. Clearly, such additional labor and time inhibit quick and reliable mounting of window film sheet structures to frames and the like.
Unless the window films are properly applied to windows, there is a chance that they will crease and fold, during cutting and installation due to their inherent highly flexible nature. As such there is a chance that they will cause permanent flaws in the film which inhibit their optical properties after being applied. Some of these window films include UV blocking materials that may in certain circumstance even damage the underlying window to which they are applied. As such, it is desired to avoid having the film contact the window.
Also, such window film sheet structures are typically provided with an adhesive layer. The adhesive layer is exposed following removal of a low adhesion release liner and mounted to a window casement or the like. Cutting and installing such thin films tends to be prolematic due to their very flexible nature as well as the adhesive layer sticking to itself in the process. As such, this tends to limit its use in a do-it-yourself application. Also, direct application of the adhesive layers to window casements or the like inhibits reuse from heating season to heating season since the adhesive qualities tend to diminish through repeated usage.
Thus, due to the number and complexity of steps involved in installing inherently flimsy film, along with the adhesive issues associated with installing thin window films, the prior approaches are generally considered time consuming, demanding, as well as potentially costly. These burdens are even more pronounced particularly in the do-it-yourself field, wherein a typical installer has very little experiences handling these materials.
Without the foregoing issues being satisfied, the true potential of successfully applying window film sheet structures providing for thermal insulation as well as avoiding permanent flaws due to their flimsy nature and adhesive qualities may not be fully achieved, especially in a simple, reliable, less time consuming, and less costly manner.
The present invention provides enhanced methods, an apparatus, methods of making such apparatus, and a kit adapted for making window film frames that are adapted for installation over transparent panels, such as windows in a manner that represents improvements over prior art approaches.
The present invention relates generally to frame assemblies carrying films and, more particularly, to window film frame assemblies adapted for installation over windows as well as maintaining their optical properties. The present invention provides a film frame assembly that comprises: a frame defining a frame opening; one or more pressure-sensitive adhesive portions on at least one side of the frame, and a generally flexible film sheet structure attached to the one or more pressure-sensitive adhesive portions for covering the frame opening, wherein the film sheet structure has stiffness so as to conform to the shape of the film structure across the frame opening.
The present invention provides a method of making a window film frame assembly adapted for use in combination with an opening in a window assembly, the method that comprises: providing a frame defining a frame opening, applying one or more pressure-sensitive adhesive portions to at least one side of the frame, attaching a generally flexible film sheet structure to the adhesive portions wherein the film sheet structure has stiffness so as to conform to the shape of the film structure across the frame opening.
The present invention provides a kit that comprises: a frame defining a frame opening; one or more pressure-sensitive adhesive portions on at least one side of the frame; and a generally flexible film sheet structure that is attachable to the one or more pressure-sensitive adhesive portions for covering a frame opening. The flexible film sheet structure has stiffness such that the film sheet structure generally conforms to the shape of the film structure across the frame opening.
An aspect of the invention is the provision of a method, apparatus, and kit for providing a window film frame assembly adapted for installation over a window assembly.
An aspect of the present invention is a method, apparatus, and kit that achieve the foregoing in a manner that obtains the benefits of installation over window film assemblies by using window film sheet structures that do not require adhesives.
An aspect of the present invention is a method, apparatus, and kit that that are adapted to use window film sheet structures to achieve the foregoing in a manner that minimizes significant distortion of viewable images therethrough.
An aspect of the present invention is a method, apparatus, and kit that are adapted for using window film sheet structures for installation over windows as well as for maintaining their optical properties.
An aspect of the present invention is a method, apparatus, and kit that achieve the foregoing in a manner that minimizes significantly the costs and labor associated with making such window film frame structures.
Another aspect of the present invention is a method, apparatus, and kit that achieve the foregoing in a manner that increases significantly the reliability and ease of installing, such window film sheet structures particularly in a do-it-yourself environment.
The aspects described herein are merely a few of the several that can be achieved by using the present invention. The foregoing descriptions thereof do not suggest that the invention must only be utilized in a specific manner to attain the foregoing aspects.
These and other features and aspects of this invention will be more fully understood from the following detailed description of the preferred embodiments. It should be understood that the foregoing generalized description and the following detailed descriptions are exemplary and are not restrictive of the invention.
The words “a”, “an”, and “the” are used interchangeably with “at least one” to mean one or more of the elements being described. By using words of orientation, such as “top”, “bottom”, “overlying”, “front”, “back” and “backing” and the like for the location of various elements in the disclosed articles, we refer to the relative position of an element with respect to a horizontally-disposed body portion. It is not intended that the disclosed articles should have any particular orientation in space during or after their manufacture.
Reference is made to
The window film frame assembly 10 essentially includes a frame assembly 18 (
Typically, frame assemblies of this type include four elongated frame segments, each having generally uniform cross-sections that are interconnected together as will be described by the interconnecting frame corner connector members 24. While a rectangular frame assembly is illustrated, it will be understood that other geometric configurations are envisioned for purposes of matching the contour of the opening into which it is to be installed.
As noted, the corner connector members 24 join together the frame segments 22 to form the frame assembly 18 and define a frame opening 26 (
Before making the window film frame assembly 10, the size and shape of the opening 12 are determined. As seen in
In this embodiment, the window film sheet structure 20 may be a transparent plastic material that is flexible and yet has sufficient stiffness so that it can retain its dimensions and shape. In addition, the window film sheet structure 20 is to have its major exterior surfaces without an adhesive layer. There are a number of approaches for attaining such a configuration within the spirit and scope of this invention.
In one illustrated embodiment (see
The window film sheet structures may be selected from a group of window film structures that comprises solar window film, privacy window film, security window film, graphic design film, frosted finish film or any combination thereof. The foregoing films may reflect ultraviolet and infrared solar energy as well as posses other known characteristics.
Provision is made for a kit 50 (see
The frame assembly 18 may then be test fit (see
As illustrated in
In order to implement the foregoing, the present invention provides of a kit 50 as follows. This kit 50 is to be used in the context of a do-it-yourself environment. It includes as noted, four metal frame segments 22 as well as a plurality of frame corner connector members 24; a web of the window film sheet structure 20; a roll 42 of pressure sensitive stripes 40, a cutting tool 30, as well as a set of instructions.
The above embodiments have been described as being accomplished in a particular sequence, it will be appreciated that such sequences of the operations may change and still remain within the scope of the invention. Also other procedures may be added.
This invention may take on various modifications and alterations without departing from the spirit and scope. Accordingly, this invention is not limited to the above-described embodiments, but is to be controlled by limitations set forth in the following claims and any equivalents thereof.
This invention also may be suitably practiced in the absence of any element not specifically disclosed herein. All patents and publications noted above, including any in the Background section are incorporated by reference into this document in total.
The present application is related to co-pending and commonly assigned U.S. Patent applications: U.S. Patent Application (Attorney Docket No. 62687US002), entitled “Window Film Assembly And Method Of Installing”; U.S. Patent Application (Attorney Docket No. 62689US002) entitled “Apparatus For Mounting Film Structures And Methods”, U.S. Patent Applications (Attorney Docket No. 62690US002) entitled “Apparatus For Mounting Laminates On Substrates And Methods Thereof”; all of which are filed concurrently herewith.