Reinforcing structure for a window frame system

Abstract

A method of reinforcing and sealing a composite frame is provided. The method includes receiving material for processing, the material having surfaces defining at least one continuous channel therein; cutting the received material to a desired length; forming at least one notch in the material by cutting the material at certain angles thereby defining a pair of notch surfaces; placing reinforcing structures and sealing measures within at least a portion of the channel; and folding the material at the notch so that the notch surfaces are in abutting relation and moving the ends to be in abutting relating to define a closed frame. The reinforcing and sealing structure increases the structural integrity of the frame and provides a seal tight exterior as well as an aesthetically pleasing finished product.

Description

This application is a Continuation-in-Part of U.S. patent application Ser. No. 10/175,021, filed on Jun. 18, 2002, which is a continuation of U.S. patent application Ser. No. 09/679,220, filed on Oct. 3, 2000, now U.S. Pat. No 6,678,934 B1, which in turn is based on Provisional Patent Application Ser. No. 60/157,625, which was filed on Oct. 4, 1999, and priority is claimed thereto.

FIELD OF THE INVENTION

This invention relates to the production of window frame systems and, more particularly, to structure for reinforcing and sealing composite window frames.

BACKGROUND OF THE INVENTION

Window frames made of composite material such as vinyl have gained popularity due to their lightweight and corrosion resistance. However the production process is long, tedious and marred with inconsistencies in quality, physical dimensions and architectural nature the corners and other joints of conventional composite windows may not be sufficiently robust due to the material having low rigidity, becoming brittle and damaged by the clean up process. Thus, there is a need to provide a reinforcing structure to strengthen a composite window frame and a mechanism for sealing the corner from air and water infiltration.

SUMMARY OF INVENTION

An object of the invention is to fulfill the need referred to above. In accordance with the principles of the present invention, this objective is achieved by a method of creating a better process for producing the window system as well as sealing and reinforcing a composite frame. The method includes receiving material for processing, the material having surfaces defining at least one continuous channel therein; cutting the received material to a desired length; forming at least one notch in the material by cutting the material at certain angles thereby defining a pair of notch surfaces; placing reinforcing structure within at least a portion of the channel; and folding the material at the notch so that the notch surfaces are in abutting relation and moving the ends to be in abutting relating to define a closed frame with the reinforcing structure, disposed within the channel in the closed frame, providing sealing properties and reinforcement to the frame.

In accordance with another aspect of the invention, a frame structure includes a composite frame defining a closed structure. The closed structure has an interior periphery defining a portion of a continuous channel in the frame. A reinforcing structure includes a main body secured within the channel at a certain location, and a cable structure or roll-formed metallurgical materials having first and second ends. The first end is coupled with the main body. The cable structure extends from the certain location about the periphery and within the continuous channel and back generally to the certain location with the second end being secured to the main body so that the cable structure provides compression to the frame.

Other objects, features, functionality and characteristics of the present invention, as well as the methods of operation and the functions of the related elements of the structure, the combination of parts and economics of manufacture will become more apparent upon consideration of the following detailed description and appended claims with reference to the accompanying drawings, all of which form a part of this specification.

BRIEF DESCRIPTION OF DRAWINGS

The invention will be better understood from the following detailed description of the preferred embodiments thereof, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts, in which:

FIG. 1 is a side view of a linear profile being cut, notched and processed to be used as a window frame in accordance with the principles of the invention.

FIG. 2 is a perspective view of the cut, processed and notched profile of FIG. 1.

FIG. 3 is a perspective view of the profile of FIG. 2 being folded at the notches to define a window frame.

FIG. 4 is a perspective view of the frame of FIG. 3 shows a pre-assembled, processed and folded frame and prior to glazing.

FIG. 5 is a front view of an assembled frame of FIG. 4 after glazing and including a reinforcing and sealing structure in accordance with an embodiment of the invention.

FIG. 6 is an enlarged view of the corner portion depicting the insertion cam with a threaded core used to tighten the frame and create sealing properties in the corners or joints of the frame encircled at 6 in FIG. 5.

FIG. 7 a perspective view of the corners cam system from an exterior portion of FIG. 6.

FIGS. 8a-8f are front views of window frame systems of various shapes, each including the reinforcing and sealing structure of FIG. 6.

FIG. 9 is a perspective view of a corner portion of a frame system showing a reinforcing and sealing structure utilizing a one-way tension strap interlocking mechanism in accordance with another embodiment of the invention.

FIG. 10 is a perspective view of a corner portion of a frame system showing dual one-way tension strap interlocking mechanisms used for reinforcing and sealing structures of FIG. 9.

FIG. 11 is a side view of a linear profile including corner reinforcing and sealing structure in accordance with still another embodiment of the invention.

FIG. 12 is a front view of a window frame formed by folding the profile of FIG. 11 and shown with the reinforcing and sealing structure in an operative position.

FIG. 13 is an enlarged view of a reverse flex cam interlocking coupling device for reinforcing and sealing structure of FIG. 12.

FIG. 14 is a front view of a widow frame system including corner reinforcing and sealing structures in accordance with yet another embodiment of the invention.

FIG. 15 is an enlarged, sectional view of the internal interlocking system portion encircled at 15 in FIG. 14.

FIG. 16 is a cut-away view of a widow frame including individual components that comprise a reinforcing and sealing structure in accordance with yet another embodiment of the invention.

FIG. 17 is a view of a window frame including exterior gel-coat applied material used as a reinforcing and sealing structure in accordance with an embodiment of the invention.

FIG. 18 is a front view of a window frame including multiple corner tension plug clips used as restrictors from separation and utilized in combination as a reinforcing structure in accordance with yet another embodiment of the invention.

FIG. 19 is a perspective view of a corner portion of a frame system showing another internal embodiment restricting shear or tensile degradation to the frame and used as a reinforcing and sealing structure.

FIG. 20 is a front view of a window frame including an internal bladder comprised of a polymer material as a reinforcing and sealing structure in accordance with yet another embodiment of the invention.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EXEMPLARY EMBODIMENTS

With reference to FIG. 1, a side view of a profile 10, prior to folding, but after being notched and cut is shown in accordance with the principles of the present invention. The profile 10 is employed as a frame of a window system, as will be explained more fully below. The profile 10 is preferably made of a synthetic material or composition, including typically vinyl, wood composite, plastic, metal, resin, fiberglass, PVC, Cellular PVC, ABS, co-extrusion, pultrusion and/or fiber wound bendable material. As shown in FIG. 1 each end 12 and 14 is cut by tooling 15 at generally a 45-degree angle. Notches 18, for defining corners of the frame, are cut into the profile 10 at certain locations via tooling 17. The notches 18 are formed by cutting the profile at certain angles, thereby defining a pair of notch surfaces 11, 13 at each notch 18. Also, vent, subcomponent assemblies and drain holes 20 are provided in the profile 10 via tooling 19.

FIG. 2 is a perspective view of a typical new construction profile 10 after the ends 12 and 14 and notches 18 have been formed or cut. A nail fin 22 extends from a bottom of the profile 10 but can be trimmed back at a 90 degree angle. A glazing bead track 24 is provided adjacent to a glass track 26, the other side of which is formed by a glass tower 28. The glass tower 28 and a vent tower 30 form walls of a vent track 32. Weep/drainage holes 34 are in communication with the holes 20 to permit water to drain from the frame.

With reference to FIG. 3, folding of the profile 10 of FIG. 2 is shown to provide a closed structure. In the embodiment, the closed structure is a rectangular frame, generally indicated at 36, in FIG. 4. More particularly, the profile 10 is folded at the notches 18 causing surfaces 11 and 13 to be in abutting relation to define corners 38, 40 and 42. Ends 12 and 14 are brought into abutting relation to define corner 44 (FIG. 4). The process of manufacturing the frame 36 is described in my earlier U.S. Pat. No. 6,678,934, the content of which is hereby incorporated into the present specification by reference.

A completed window frame assembly, generally indicated at 46, is shown in FIG. 5 including the frame 36, upper glazing 48, lower glazing 50 and meeting rail 52. Reinforcing and sealing structure, in accordance with an embodiment of the invention, is shown generally indicated 54 in FIG. 5 and is best shown in FIGS. 6 and 7. The reinforcing structure 54 includes a main body 56 secured within a continuous channel 58 defined in part by an interior periphery 61 of the closed frame 36. The reinforcing and sealing structure 54 also includes a cable structure 60. The cable structure 60 has a first end 59 fixed to or integral with the body 56 at one corner of the frame 36, for example, corner 44. As shown in FIG. 5, the cable structure 60 extends from corner 44 within the channel 58, around corners 38, 40, 40 and back the corner 44 and thus to the main body 56.

Hence, with reference to FIG. 6, a second end 62 of the cable structure 60 is coupled with a movable member 64. In the embodiment of FIGS. 6 and 7, the movable member 64 is in treaded engagement with the main body 56 so that tension of the cable structure 60 can be adjusted. More particularly, access to the movable member 64 can be obtained through opening 66 in the frame 36 and the movable member 64 can be moved via threaded engagement in opposite directions to adjust the tension of the cable structure 60. Once the desired tension is set, the opening 66 in the frame can be sealed. Since the cable structure 60 is disposed about the entire periphery of the glazings 48 and 50, the cable structure 60 compresses the frame 36, maintaining abutting corner surfaces in abutting relation to provide a more robust window system 46.

The reinforcing structure 54 can be employed in windows system of various shapes. For example, FIGS. 8a-8f show window frame systems having frames 36a-36f, respectively, of various shapes with each frame including the reinforcing structure 54.

With reference to FIG. 9, another embodiment of the reinforcing and sealing structure is shown generally indicated at 54′. Reinforcing and sealing structure 54′ is preferably a conventional bundle tie or gear track system of the type described in U.S. Pat. No. 3,887,965, the contents of which is hereby incorporated into the present specification by reference. Thus, the reinforcing and structure 54′ has a main body 56′ integral with a first end 59′ of the cable structure 60′. The main body 56 has an internal member (not shown) that adjustably engages external teeth 68 of end 62′ of the cable structure 60′ to set the desired tension of the cable structure 60′. FIG. 10 shows the use of two reinforcing and sealing structures 54′ in a single frame 36. The reinforcing and sealing structure 54′ can be employed in frames having the shapes shown in FIGS. 8a-8f.

The reinforcing and sealing structure 54 or 54′ is placed in the channel 58 when the profile 10 is in the non-folded condition (FIG. 1). The profile 10 is then folded at the notches 18 with the ends 12 and 14 placed in abutting relation. Thereafter, the second end 62 or 62′ of the cable structure is adjustably secured to the main body of the reinforcing structure.

With reference to FIG. 11, another embodiment of a reinforcing and sealing structure is shown, generally indicated at 68, in the profile 10 prior to folding thereof. The reinforcing and sealing structure 68 includes a mechanism 70 placed in each notch 18 in the profile 10, extending into channel 58. As best shown in FIG. 13, each mechanism 70 includes a pair of elements 72, 74 that preferably pivot with respect to base 76 from an inoperative position (dashed lines in FIGS. 11 and 13) to an operative position (solid lines in FIG. 13 and dashed lines in FIG. 12). Thus, when each mechanism 70 is placed at each corner formed by the notch 18, the elements 72, 74 are in an inoperative position, and during the folding step, the elements 72, 74 pivot about base 76 to the operative position maintaining the pair of notch surfaces 11, 13 in abutting relation. The base 76 also adds rigidity to the associated corner. Each mechanism 70 includes ratchet structure 78 to lock the elements 72, 74 in the operative position. This mechanism 70 preferably also includes a hollow core 75 that is used as a conduit to the sealing points of the frame so that a sealing material can be applied via injection through the mechanism 70 and applied as needed or desired to the required application point via the conduit in core 75.

Instead of providing the ratchet and having each element 72, 74 extend separately into in an associated frame segment as shown in FIG. 12, the elements 72, 74 can be configured to engage or interlock at a corner upon folding the profile 10 at the notch when defining the corner. Corner 44 formed by the abutting ends 12 and 14 of the profile 10 preferably includes a non-pivoting reinforcing structure 80 for ease of assembly. Reinforcing structure 80 can be of the type shown in FIG. 15, as will be described below.

With reference to FIGS. 14 and 15, another embodiment of reinforcing and sealing structure, generally indicated at 80, includes a pair of members 82, 84 within channel 58 at each corner. One member 82 of each pair is disposed transversely with respect to the other member 84 of the pair. A locking member, preferably in the form of a pin 86 secures the members 82, 84 together in abutting relation. An opening 88 is provided in the frame 36 for inserting the pin 86. The members 82 and 84 can be placed prior to folding of the profile 10 and then after folding the profile 10 to define the closed frame 36, the pin 86 can be used to secure the members 82 and 84 to maintain the corner surfaces in abutting relation.

FIG. 16 shows another embodiment of reinforcing and sealing structure, generally indicated at 90. The reinforcing structure 90 includes a plurality of clips that are fixed about portions of corners of the vent tower 30, which generally tends to be the weak point of current thermal applied corner applications. The clips simply slip over portion of the vent tower to increase structural integrity of the frame 36.

FIG. 17 shows a reinforcing and sealing structure in the form of a plate 92 secured to each exterior corner of the frame 36 to increase sealing performance as well structural integrity of the frame 36. It can be appreciated that the plate 92 can be provided at any corner portion (interior or exterior) of the frame 36.

FIG. 18 shows yet another embodiment of reinforcing and sealing structure, generally indicated at 94. A reinforcing structure 94 is provided at each interior corner of the frame 36 and is in the form of a generally L-shaped bracket 96 having locking tabs 98 extending there-from that are received in associated recesses 100 provided in the frame 36.

FIG. 19 shows still another embodiment of reinforcing structure, generally indicated at 102. A reinforcing structure 102 is provided at each corner of the frame 36 and is in the form of a generally L-shaped member 104 having a first portion 106 and a second portion 108. The first portion has serrations 110 for engaging surfaces defining a channel 112 in the glass tower 28. Portion 108 is generally smooth for ease of insertion into a channel of a glass tower of an adjacent section (not shown) of the profile 10. Portion 106 can be inserted prior to folding of the profile and portion 108 can be inserted during the folding of the profile 10 to define the frame.

It can be appreciated that other methods for providing structural or sealing integrity to a composite frame can include, for example, injecting polymer 114 into the corners or entire hollow portions of the frame 36 (FIG. 20), using a polymer gel coating application in conjunction with a mechanical reinforcing structure at the corners of the frame, and hot plate welding of the abutting corner surfaces prior to assembling the folded profile 10. The reinforcing and sealing structure increases the structural integrity of the frame and provides a seal tight exterior as well as an aesthetically pleasing finished product.

Although the reinforcing and sealing structure has been described with a profile 10 that is folded to define a frame 36, it can be appreciated that the reinforcing structure can be used in a frame manufactured by other methods such as joining separate profile segments. In addition, adhesive, clips, and/or fasteners and the like can be employed to help mount the reinforcing structure within the frame 36. Furthermore, the various embodiments of the reinforcing and sealing structure described herein can be used in combination with each other within a common frame.

The window frame system can be formed in a wide range of window shapes and configurations, including but not limited to squares, rectangles, triangles and other polygons, curved sides, including rounds, half rounds, circle segments, and other curved shapes, single hung, double hung, main frame, slider, fixed frame, vent or sash, patio door, screen door, storm door, casement/awning and the like.

The foregoing preferred embodiments have been shown and described for the purposes of illustrating the structural and functional principles of the present invention, as well as illustrating the methods of employing the preferred embodiments and are subject to change without departing from such principles. Therefore, this invention includes all modifications encompassed within the spirit of the following claims.

Claims

1. A method of reinforcing a composite frame, the method including:

receiving material for processing, the material having surfaces defining at least one continuous channel therein,

cutting the received material to a desired length,

forming at least one notch in the material by cutting the material at certain angles thereby defining a pair of notch surfaces,

placing reinforcing structure within at least a portion of the channel, and

thereafter, folding the material at the notch so that the notch surfaces are in abutting relation and moving the ends to be in abutting relating to define a closed frame with the reinforcing structure, disposed within the channel in the closed frame, providing reinforcement to the frame.

2. The method of claim 1, wherein the reinforcing structure has a main body and a cable structure having first and second ends, the first end being coupled with the main body, the placing step including securing the main body within the channel at a certain location and orienting the cable structure to extend from the certain location within the entire continuous channel and back generally to the certain location, and securing the second end to the main body so that the cable structure provides compression to the frame.

3. The method of claim 2, wherein the second end of the cable structure is adjustably coupled with the main body to control tension of the cable structure, the method including adjustably securing the second end to the main body to control tension of the cable structure.

4. The method of claim 1, wherein the frame is composed of vinyl.

5. The method of claim 1, wherein the frame is a window frame.

6. The method of claim 1, wherein a corner is formed by the abutting ends and another corner is formed at the notch by the abutting notch surfaces, and wherein the placing step includes placing a reinforcing structure at each said corner.

7. The method of claim 6, wherein the reinforcing structure at the corner formed by the notch is a mechanism constructed and arranged to maintain the notch surfaces in abutting relation.

8. The method of claim 7, wherein the mechanism includes a pair of pivoting elements, such that when the reinforcing structure is placed at the corner formed by the notch, the elements are in an inoperative position, and during the folding step, the elements pivot to an operative position maintaining the notch surfaces in abutting relation.

9. The method of claim 8, wherein each member has a hollow core defining a conduit through which a sealant can be injected to application points of the frame.

10. The method of claim 8, wherein the mechanism includes ratchet structure to lock the elements in the operative position.

11. The method of claim 6, wherein the reinforcing structure includes a pair of members at each corner, one member of each pair being disposed transversely with respect to the other member of the pair, a locking member securing the members together in abutting relation.

12. The method of claim 6, wherein the frame is a window frame having a glass tower, the channel being defined in the glass tower, the reinforcing structure including a generally L-shaped member, the placing step including placing at least a portion of an L-shaped member in the channel of the glass tower at each corner.

13. A reinforcing structure for a composite frame, the frame defining a closed structure, the closed structure having an interior periphery defining a portion of a continuous channel in the frame, the reinforcing structure comprising:

a main body constructed and arranged to be secured within the channel at a certain location, and

a cable structure having first and second ends, the first end being coupled with the main body, and the cable structure being of a length sufficient to extend from the certain location about the periphery and within the continuous channel and back generally to the certain location so that the second end of the cable structure can be secured to the main body so that the cable structure can provide compression to the frame.

14. The reinforcing structure of claim 13, wherein the second end of the cable structure is constructed and arranged to be adjustably coupled with the main body to control tension of the cable structure.

15. The reinforcing structure of claim 14, wherein the second end of the cable structure and the main body are constructed and arranged to be in adjustable treaded engagement.

16. The reinforcing structure of claim 14, wherein the first end of the cable structure is integral with the main body and wherein the second end of the cable structure has a plurality of locking teeth and the main body is constructed and arranged to engage certain of the locking teeth.

17. A frame structure comprising:

a composite frame defining a closed structure, the closed structure having an interior periphery defining a portion of a continuous channel in the frame, and

a reinforcing structure comprising: a main body secured within the channel at a certain location, and a cable structure having first and second ends, the first end being coupled with the main body, and the cable structure extending from the certain location about the periphery and within the continuous channel and back generally to the certain location with the second end being secured to the main body so that the cable structure provides compression to the frame.

18. The frame structure of claim 17, wherein the second end of the cable structure is adjustably coupled with the main body to control tension of the cable structure.

19. The frame structure of claim 18, wherein the second end of the cable structure and the main body are constructed and arranged to be in adjustable treaded engagement.

20. The frame structure of claim 18, wherein the first end of the cable structure is integral with the main body and wherein the second end of the cable structure has a plurality of locking teeth and the main body engages certain of the locking teeth.

21. The frame structure of claim 17, wherein the frame is composed of vinyl.

22. The frame structure of claim 21, wherein the frame is a window frame.

23. A method of providing compression to a composite frame, the frame defining a closed structure having a periphery defining a portion of a continuous channel in the frame, the method including:

providing a reinforcing structure having a main body and a cable structure having first and second ends, the first end being coupled with the main body,

securing the main body within the channel at a certain location,

orienting the cable structure to extend from the certain location about the periphery and within the continuous channel and back generally to the certain location, and

securing the second end to the main body so that the cable structure provides compression to the frame.

24. The method of claim 23, wherein the second end of the cable structure is adjustably coupled with the main body to control tension of the cable structure, the method including adjustably securing the second end to the main body to control tension of the cable structure.

25. The method of claim 23, further including sealing at least portions of the frame by applying a gel coating to the portions.