Screen frame and adapter for universal installation within different sized window/door sockets

Abstract

A particularly formed frame and corresponding adapters permit installation of a screen assembly into different windows or doors having different socket widths, reducing the required number of SKUs that need to be stocked. The adapter includes: a base portion; a stem portion; and a bulb portion. The frame includes a plurality of recesses, each configured to slidably receive an adapter therein. The width of the frame is sized to be received in a first door/window socket having a first socket width. When a first sized adapter having a first bulb size is installed in each recess, the width of the frame and the protruding distance of the first bulb size are configured to be received in a second door/window socket having a second socket width. A second sized adapter having a second bulb size may instead be installed for use in a second door/window socket having a second socket width.

Claims

1. A combination frame and adapter for a screen assembly, for use in enabling universal installation of the screen assembly into different windows or doors having different socket widths; wherein said adapter comprises: a base portion; a stem portion, said stem portion being substantially cylindrical and being configured to extend away from said base portion to a distal end of said stem portion; and a bulb portion, said bulb portion configured to extend away from said distal end of said stem portion, and be symmetrically formed with respect to an axis of said cylindrical stem portion; wherein said frame comprises: at least one opening on a first portion of said frame each configured to form a recess and two protruding flange ends, each said at least one opening being configured to slidably receive a respective said adapter, with said base portion positioned within said recess, with said cylindrical stem positioned between said two protruding flange ends, and with said bulb portion positioned and configured to overhang said two protruding flange ends and to protrude from a first side of said frame; and at least one opening on a second portion of said frame each configured to form a recess and two protruding flange ends, each said at least one opening in said second portion of said frame being configured to slidably and correspondingly receive a respective said adapter, each with said bulb portion positioned to protrude from said first side of said frame; wherein said frame comprises a width configured to be received in a first door/window socket having a first socket width; and wherein each said bulb portion protrudes a distance away from said first side of said frame when said respective adapters are installed in said frame, and wherein said width of said frame and said protruding distance of each said bulb portion are configured to be received in a second door/window socket having a second socket width.

2. The combination frame and adapter for a screen assembly according to claim 1, wherein said at least one opening on said first portion of said frame comprises a first opening and a second opening configured to respectively receive said first adapter and a third said adapter; and wherein said at least one opening on said second portion of said frame comprises a third opening and a fourth opening configured to respectively receive said second adapter and a fourth said adapter.

3. The combination frame and adapter for a screen assembly according to claim 2, wherein said frame is rectangular shaped having a first corner, a second corner, a third corner, and a fourth corner; and wherein each of said first opening, said second opening, said third opening, and said fourth opening are respectively positioned proximate to said first corner, said second corner, said third corner, and said fourth corner, to respectively position each of said first adapter, said third adapter, said second adapter, and said fourth adapter proximate to said first corner, said second corner, said third corner, and said fourth corner.

4. The combination frame and adapter for a screen assembly according to claim 1, wherein said bulb portion comprises at least a portion of a hemispherical surface.

5. The combination frame and adapter for a screen assembly according to claim 1, wherein said protruding distance of each said bulb portion and said width of said frame are configured to be received in the second socket width in a friction fit.

6. The combination frame and adapter for a screen assembly according to claim 1, wherein said protruding distance of each said bulb portion and said width of said frame are configured to be received in the second socket width in a clearance fit.

7. A combination frame and adapter for a screen assembly, for use in enabling universal installation of the screen assembly into different windows or doors having different socket widths; wherein said adapter comprises: a base portion; a stem portion, said stem portion being substantially cylindrical and being configured to extend away from said base portion to a distal end of said stem portion; and a bulb portion, said bulb portion configured to extend away from said distal end of said stem portion, and be symmetrically formed with respect to an axis of said cylindrical stem portion; wherein said frame comprises at least one opening on a first portion of said frame being configured to slidably receive a first said adapter, and at least one opening on a second portion of said frame being configured to slidably receive a second said adapter; wherein said frame comprises a width configured to be received in a first door/window socket having a first socket width; and wherein each said bulb portion protrudes a distance away from a first side of said frame when said adapters are installed in said frame, and wherein said width of said frame and said protruding distance of each said bulb are configured to be received in a second door/window socket having a second socket width.

8. The combination frame and adapter for a screen assembly according to claim 7, wherein said at least one opening on said first portion of said frame comprises a first opening and a second opening configured to respectively receive said first adapter and a third said adapter, and wherein said at least one opening on said second portion of said frame comprises a third opening and a fourth opening configured to respectively receive said second adapter and a fourth said adapter.

9. The combination frame and adapter for a screen assembly according to claim 8, wherein said frame is rectangular shaped having a first corner, a second corner, a third corner, and a fourth corner; and wherein each of said first opening, said second opening, said third opening, and said fourth opening are respectively positioned proximate to said first corner, said second corner, said third corner, and said fourth corner, to respectively position each of said first adapter, said third adapter, said second adapter, and said fourth adapter proximate to said first corner, said second corner, said third corner, and said fourth corner.

10. The combination frame and adapter for a screen assembly according to claim 7, wherein said bulb portion comprises at least a portion of a hemispherical surface.

11. The combination frame and adapter for a screen assembly according to claim 7, wherein said protruding distance of each said bulb portion and said width of said frame are configured to be received in the second socket width in a friction fit.

12. The combination frame and adapter for a screen assembly according to claim 7, wherein said protruding distance of each said bulb portion and said width of said frame are configured to be received in the second socket width in a clearance fit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The description of the various example embodiments is explained in conjunction with appended drawings, in which:

(2) FIG. 1 illustrates a front view of a portion of a frame for a screen formed in accordance with the present invention;

(3) FIG. 1A illustrates a front view of a portion of a frame for a screen formed in accordance with another embodiment of the present invention;

(4) FIG. 2 illustrates an end view through the portion of a frame for a screen as shown in FIG. 1;

(5) FIG. 3 is an end view of a first adapter of the present invention;

(6) FIG. 3A is an end view of a different version of the first adapter of FIG. 3, being formed without an overhanging rounded bulb portion.

(7) FIG. 4 is an end view of a second adapter of the present invention;

(8) FIG. 5 illustrates a top view of a first embodiment of the adapters of the present invention;

(9) FIG. 6 illustrates a top view of a second embodiment of the adapters of the present invention;

(10) FIG. 7 shows the adapter of FIG. 3 prior to being received in the recess of the frame portion shown in FIG. 3;

(11) FIG. 8 shows the adapter of FIG. 3 after being received in the recess of the frame portion shown in FIG. 3;

(12) FIG. 9 is a front view of a frame for a screen assembly formed in accordance with the present invention;

(13) FIG. 10 is a front view showing a screen assembly formed in accordance with the present invention, having two adapters positioned on each of the upper sand lower side members of the frame;

(14) FIG. 11 is a front view showing a screen assembly formed in accordance with the present invention, having one elongated adapter installed on the upper side member of the frame, and having three small adapters positioned on the lower side member of the frame;

(15) FIG. 12 shows the frame portion of FIG. 2 prior to being received in a socket of a first window or door;

(16) FIG. 12A shows the frame portion of FIG. 2 after being received in the socket of the first window or door;

(17) FIG. 13 shows the frame portion of FIG. 2 with the first adapter of FIG. 3 mounted thereto, prior to being received in a socket of a second window or door:

(18) FIG. 13A shows the frame portion of FIG. 2 with the first adapter of FIG. 3 mounted thereto, after being received in the socket of the second window or door:

(19) FIG. 14 shows the frame portion of FIG. 2 with the second adapter of FIG. 4 mounted thereto, prior to being received in a socket of a third window or door; and

(20) FIG. 14A shows the frame portion of FIG. 2 with the second adapter of FIG. 4 mounted thereto, after being received in a socket of a third window or door.

DETAILED DESCRIPTION OF THE INVENTION

(21) As used throughout this specification, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than a mandatory sense (i.e., meaning must), as more than one embodiment of the invention may be disclosed herein. Similarly, the words “include”, “including”, and “includes” mean including but not limited to.

(22) The phrases “at least one”, “one or more”, and “and/or” may be open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A. B and C”. “one or more of A, B. and C”, and “A, B, and/or C” herein means all of the following possible combinations: A alone; or B alone; or C alone; or A and B together; or A and C together; or B and C together; or A. B and C together.

(23) Also, the disclosures of all patents, published patent applications, and non-patent literature cited within this document are incorporated herein in their entirety by reference. However, it is noted that citing herein of any patents, published patent applications, and non-patent literature is not an admission as to any of those references constituting prior art with respect to the disclosed and/or claimed apparatus/method.

(24) Furthermore, the reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection therewith is included in at least that one particular embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Additionally, the described features, advantages, and characteristics of any particular embodiment disclosed herein may be combined in any suitable manner with any of the other embodiments disclosed herein.

(25) Additionally, any approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative or qualitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as “about” is not to be limited to the precise value specified, and may include values that differ from the specified value in accordance with applicable case law. Also, in at least some instances, a numerical difference provided by the approximating language may correspond to the precision of an instrument that may be used for measuring the value. A numerical difference provided by the approximating language may also correspond to a manufacturing tolerance associated with production of the aspect/feature being quantified. Furthermore, a numerical difference provided by the approximating language may also correspond to an overall tolerance for the aspect/feature that may be derived from variations resulting from a stack up (i.e., the sum) of a multiplicity of such individual tolerances.

(26) Any use of a friction fit (i.e., an interface fit) between two mating parts described herein indicates that the opening (e.g., a hole) is smaller than the part received therein (e.g., a shaft), which may be a slight interference in one embodiment in the range of 0.0001 inches to 0.0003 inches, or an interference of 0.0003 inches to 0.0007 inches in another embodiment, or an interference of 0.0007 inches to 0.0010 inches in yet another embodiment, or a combination of such ranges. Other values for the interference may also be used in different configurations (see e.g., “Press Fit Engineering and Design Calculator,” available at: www.engineersedge.com/calculators/machine-design/press-fit/press-fit-calculator.htm).

(27) Any described use of a clearance fit indicates that the opening (e.g., a hole) is larger than the part received therein (e.g., a shaft), enabling the two parts to move (e.g. to slide and/or rotate) when assembled, where the gap between the opening and the part may depend upon the size of the part and the type of clearance fit—i.e., loose running, free running, easy running, close running, and sliding (e.g., for a 0.1250 inch shaft diameter the opening may be 0.1285 inches for a close running fit, and may be 0.1360 inches for a free running fit; for a 0.5000 inch diameter shaft the opening may be 0.5156 inches for a close running fit and may be 0.5312 inches for a free running fit). Other clearance amounts are used for other clearance types. See “Engineering Fit” at: https://en.wikipedia.org/wiki/Engineering_fit; and “Three General Types of Fit,” available at www.mmto.org/dclark/Reports/Encoder%20Upgrade/fittolerences%20%5BRead-Only %5D.pdf.

(28) It is further noted that any use herein of relative terms such as “top,” “bottom,” “upper,” “lower,” “vertical.” and “horizontal” are merely intended to be descriptive for the reader, based on the depiction of those features within the figures for one particular position of the device, and such terms are not intended to limit the orientation with which the device of the present invention may be utilized.

(29) In accordance with at least one embodiment of the present invention, a frame 105 for a screen assembly 100 (e.g., FIG. 10) may be particularly formed so that the screen assembly may be installed into various different windows or doors having different socket widths, when used, for some of those cases, in combination with a particularly formed first adapter 150, or a second particularly formed adapter 170.

(30) The frame 105 (e.g., FIG. 9) of a screen assembly 100 may have at least two of its four sides constructed using a particularly formed elongated member 110, which is shown in FIGS. 1-2. The elongated member 110 may have a generally rectangular cross-sectional shape, as seen in FIG. 2, that may be formed by a first wall 111, a second wall 112, a third wall 113, and a fourth wall 114. The first wall 111 and the third wall 113 may be substantially parallel, and may be spaced apart a particular width/distance WF to permit it to be installed into a first (smaller) socket size that is typically used in a window or door (e.g., 5/16.sup.th of an inch). Note, although the frame 105 is illustrated as it may be when formed through an extrusion or casting process, it may also be made through any other suitable manufacturing process, including by welding, machining, assembling parts with the use of mechanical fasteners, etc.

(31) The first wall 111 may have an opening formed therein proximate to a first side of the member, with the opening defining an interior cavity surface 111C, which opening and cavity may extend along the entire length of the elongated member 110. A transverse wall 115 may extend from one side of the opening in the first wall 111 to the third wall 113, to shorten the extent of the cavity, so as to be sized to receive a spline 106 therein in a friction fit, to secure the end of a mesh material 107 to the frame of the screen assembly 100 (see e.g., FIG. 10).

(32) In one embodiment, as seen in FIG. 2, the first wall 111 may also have a particularly shaped recess formed proximate to a second side of the member, and may have a first such recess 111Ri formed at a first end of the elongated member 110, and a second such recess 111Rii formed at a second end of the elongated member. (It is noted that in other embodiments, the recess may be formed on other portions of the elongated member 110). Also, in one embodiment the recess may be generally T-shaped. In another embodiment the recess may be generally V-shaped, and in other embodiments other shapes may be used for the recess, which other shapes may similarly provide for retention of a correspondingly shaped adapter, which is discussed hereinafter.

(33) Each recess may extend a short distance along the length of the elongated member 110, as seen in FIG. 2, or, as shown for the elongated member 110′ in FIG. 11, a single recess 111Re may extend along the entire length of the elongated member.

(34) As seen in FIG. 2, the recess 111Ri may be formed by an opening in the first wall 111, to create two protruding flange ends 111i and 111ii. In one embodiment the adapter may be supported by these two flange ends 111i and 111ii, and the recess may extend all the way to the third wall 113. In another embodiment a secondary wall 111S may be formed to reduce the depth of the recess, to enable use of less material in forming the adapter. The secondary wall 111S may be formed to be generally parallel to the first wall 111, and a first one of its ends may be formed to connect to the fourth wall 114 and a second one of its ends may connect to a wall 116 that may extend transversely from the first wall 111, to form the shallow T-shaped recess shown in the cross-sectional view of FIG. 2. Note that the recess may alternatively be formed, as shown in FIG. 2A for the elongated member 110″, to be disposed normal to the angled end of the elongated member, and the recesses 111Ri′ and 111Rii′ may furthermore have a necked down portion 111Rn at the angled end of the elongated member to assist in retaining the adapter therein until the four sides of the screen are assembled and secured together to form the frame 105. Adhesive may additionally or alternatively be used for that purpose. The recesses 111Ri′ and 111Rii′ may also be completely covered by the adapters discussed hereinafter.

(35) The first adapter 150 is shown in the end view of FIG. 3. The first adapter 150 may extend from a first end 151 to a second end 152, and may be formed to have a base portion 153 proximate to the first end 151, a stem portion 154, and a bulb portion 155 proximate to the second end 152.

(36) The base portion 153 may have a length 153L that is sized to fit within the recess between the fourth wall 114 and the transverse wall 116, which fit may be a slight clearance fit, or a slight friction fit. The base portion 153 may also have a width 153W that is sized to fit within the recess between the secondary wall 111S and the first wall 111, which fit may also be a slight clearance fit, or a slight friction fit.

(37) The stem portion 154 may be formed to extend away from the base portion 153 to a distal end at which the bulb portion 155 is formed. The stem portion 154 may have a length 154L that is sized to position the flat side of the bulbous portion 155 in close proximity to, or in contact with, the first wall 111. To place the flat side of the bulbous portion 155 in contact with the first wall 111, the length 154L of the stem portion 154 may be the same as, or slightly smaller than, the thickness of the first wall 111. The stem portion 154 may also have a width 154W that is sized to fit between the two protruding flange ends 111i and 111ii, which fit may also be a slight clearance fit, or a slight friction fit.

(38) The bulb portion 155 may be formed to extend away from the distal end of the stem portion 154. The bulb portion 155 may preferably have a length 155L that is sized to overhang the two protruding flange ends 111i and 111ii of the first wall 111. (Note that as shown in FIG. 3A the rounded bulb portion of the adapter 150′ may alternatively not be sized to overhang the two protruding flange ends 111i and 111ii of the first wall 111). The bulb portion 155 may preferably be formed with a radius at its distal end, having a radius 150R, which may assist in installing and removing of the frame from the window or door. The bulb portion 155 may preferably be formed with a width 155W that in combination with the particular width/distance WF between the first wall 111 and the second wall 112 of the frame 110 permits the frame to be installed into a larger socket size than the 5/16.sup.th of an inch socket. e.g., a ⅜.sup.th of an inch socket, in which case WF plus 155W is roughly ⅜.sup.th of an inch.

(39) The second adapter 170 is shown in the end view of FIG. 4. The second adapter 170 may be formed substantially the same as the first adapter 150, but may be formed to have a bulb portion 175 that may be formed with a width 155W that in combination with the particular width/distance WF between the exterior surfaces of the first wall 111 and the second wall 112 of the frame 110 permits it to be installed into an even larger socket size than the smaller ⅜.sup.th of an inch socket. e.g., a 7/16.sup.th of an inch socket, in which case WF plus 155W is roughly 7/16.sup.th of an inch.

(40) The first adapter 150 and second adapter 170 may each be made of any suitable materials, including, but not limited to, metal, wood, composite, plastic, rubber, etc. The first adapter 150 and second adapter 170 may each also be formed to any particular color, which may be a color that may match the different colored frames that may be used, or it may be formed of a neutral colored material. In one embodiment, the adapters may be made of polypropylene material. Also, in one embodiment, the adapters may be made of a translucent material so that the adapter may take on the color of the elongated side member into which it is installed.

(41) Each of the first adapter 150 and second adapter 170 may be made such that the profile of each of the base portion 153, the stem portion 154, and the bulb portion 155 shown in the respective end views (FIG. 3 and FIG. 4) may be revolved about a central axis Ax (FIG. 6) to form a finished part having the top view shown in FIG. 6, so that those portions of each may be generally cylindrical.

(42) Alternatively, each of the first adapter 150 and second adapter 170 may be made such that the profile of each of the base portion 153, the stem portion 154, and the bulb portion 155 shown in the respective end views (FIG. 3 and FIG. 4) are of an elongated finished part such as the one shown in FIG. 5. In at least this embodiment, the material used should be flexible enough that it can be wound and stored on a reel.

(43) For the frame 110 shown in FIG. 9, each of the recesses of the two elongated members 110 may slidably receive an adapter therein (see FIGS. 7-8), prior to the final joining of the sides of the frame, which may appear as shown in FIG. 10. Depending upon the shape of the recess that is formed, a portion of it may still be visible after the adapter is installed therein, as may be seen in the bottom of the frame 110′ of the screen assembly 100′ shown in FIG. 11.

(44) Where a screen assembly may be fairly small is size (e.g., having a pair of sides each being less than about 18 inches in length), the frame may be formed with recesses that may be proximate to each corner, so that each of a first recess, a second recess, a third recess, and a fourth recess may respectively position a first adapter, a second adapter, a third adapter, and a fourth adapter proximate to the first corner, the second corner, the third corner, and the fourth corner of the frame.

(45) Where a screen assembly may be larger in size (e.g., having a pair of sides each being greater than about 18 inches in length), the frame may be formed with the recess that may extend across the entire length of the elongated member, as discussed hereinabove (e.g., recess 111Re). Thus, the frame may receive a first adapter, a second adapter, and a third adapter (or more such adapters) in each recess on each of the two elongated members (see the bottom of the screen assembly in FIG. 11), or may alternatively receive only a single elongated adapter (see the top of the screen assembly in FIG. 1).

(46) The use of just the frame 110 in a socket of a door or window having a socket width W1 (e.g., 5/16.sup.th of an inch) without the use of any adapters secured thereto is shown in FIG. 12 and FIG. 12A, and the frame may be sized to provide a clearance fit or a slight friction fit with the socket.

(47) The use of the frame 110 in a socket of a door or window having a socket width W2 (e.g., ⅜.sup.th of an inch) with the use of adapters 150 secured thereto is shown in FIG. 13 and FIG. 13A, and the combination of the frame and adapters may provide a slight clearance fit or a slight friction fit with the socket.

(48) The use of the frame 110 in a socket of a door or window having a socket width W3 (e.g., 7/16.sup.th of an inch) with the use of adapters 175 secured thereto is shown in FIG. 14 and FIG. 14A, and the combination frame and adapter may similarly provide a slight clearance fit or a slight friction fit with the socket.

(49) In an alternative embodiment, an adapter may be used on a frame without any recesses formed therein, where the adapter only includes the bulb portion, and which adapter may be secured to the frame using adhesive.

(50) While illustrative implementations of one or more embodiments of the present invention are provided hereinabove, those skilled in the art and having the benefit of the present disclosure will appreciate that further embodiments may be implemented with various changes within the scope of the present invention. Other modifications, substitutions, omissions and changes may be made in the design, size, materials used or proportions, operating conditions, assembly sequence, or arrangement or positioning of elements and members of the exemplary embodiments without departing from the spirit of this invention.

(51) Accordingly, the breadth and scope of the present disclosure should not be limited by any of the above-described example embodiments, but should be defined only in accordance with the following claims and their equivalents.