Abstract
A fenestration assembly includes a sash, a frame surrounding the sash, and at least one screen assembly. The sash includes at least one magnet. The sash is slideably engaged with the frame. The at least one screen assembly includes a roller assembly, a control bar, and screen material attached to the roller assembly and the control bar. The roller assembly is substantially hidden from view. The control bar includes a ferromagnetic material. The screen assembly is configured to apply tension to the screen material to wind the screen material around the roller assembly and to permit the screen material to unwind from the roller assembly under a tension applied to move the control bar away from the roller assembly. The control bar automatically engages the at least one magnet of the sash when the sash is in the closed configuration to attach the control bar to the sash.
Claims
1. A fenestration assembly comprising: a sash including at least one magnet; a frame surrounding the sash, the frame including: a top portion; a bottom portion; and two jambs connecting the top portion to the bottom portion, each of the two jambs forming first slots extending lengthwise along at least a portion of the jamb between the top portion and the bottom portion, the sash slideably engaged with the two jambs between an open configuration wherein the sash is not in contact with either of the top portion or the bottom portion and a closed configuration wherein the sash is in contact with one of: the top portion and the bottom portion; and at least one screen assembly mounted in at least one of: the top portion or the bottom portion, the at least one screen assembly including: a roller assembly substantially hidden from view; a control bar extending beyond the sash and into the first slots, the control bar including a ferromagnetic material; and a screen material attached to the roller assembly, an end of the screen material connected to the control bar, the screen assembly configured to apply tension to the screen material to wind the screen material around the roller assembly and to permit the screen material to unwind from the roller assembly under a tension applied to move the control bar away from the roller assembly, wherein the control bar automatically engages the at least one magnet of the sash when the sash is in the closed configuration to attach the control bar to the sash; and wherein the sash is configured to tilt out of a plane formed by the frame, automatically disengaging the control bar from the at least one magnet of the sash.
2. The fenestration assembly of claim 1, wherein the at least one magnet is continuously moveable between a first position wherein the at least one magnet does not project beyond a surface of the sash and a second position wherein a portion of the at least one magnet projects beyond the surface of the sash.
3. The fenestration assembly of claim 1, wherein each of the first slots includes a stop, the stops configured to prevent movement of the control bar beyond the stops and automatically disengage the control bar from the at least one magnet if the sash moves beyond the stops.
4. The fenestration assembly of claim 1, wherein the sash further includes at least one ejector facing the control bar, the at least one ejector moveable between a first position wherein the at least one ejector is at or below a surface of the sash and a second position wherein a portion of the at least one ejector projects beyond the surface of the sash to disengage the control bar from the at least one magnet.
5. The fenestration assembly of claim 4, wherein the sash further includes a ribbon connected to the at least one ejector and configured such that pulling on the ribbon moves the at least one ejector to the second position.
6. The fenestration assembly of claim 1, wherein the at least one magnet is a cylindrical magnet having a longitudinal axis, the cylindrical magnet polarized across its diameter such that rotating the cylindrical magnet about its longitudinal axis varies a magnetic force in a direction of the control bar between a first level of the magnetic force sufficient to engage the control bar and a second level of the magnetic force insufficient to engage the control bar.
7. The fenestration assembly of claim 1, wherein: the sash is a first sash and the fenestration assembly further includes a second sash; and the at least one screen assembly is a first screen assembly and a second screen assembly, wherein the first screen assembly is mounted in the bottom portion and the second screen assembly is mounted in the top portion.
8. The fenestration assembly of claim 7, wherein the fenestration assembly is a double-hung window.
9. The fenestration assembly of claim 1, wherein the end of the screen material automatically attaches to the sash via the magnet when the sash is closed.
10. The fenestration assembly of claim 1, further comprising an angled rail slope on the sash adjacent to the end of the screen material, the angled rail slope configured to facilitate the disengagement of the end of the screen material from the sash during the tilting of the sash.
11. A fenestration assembly comprising: at least one sash including: an upper rail; a lower rail; two stiles connecting the upper rail to the lower rail; and at least one magnet, the at least one magnet continuously moveable between a first position wherein the at least one magnet does not project beyond a surface of the sash and a second position wherein a portion of the at least one magnet projects beyond the surface of the sash; a frame surrounding the at least one sash, the frame including: a top portion; a bottom portion; and two jambs connecting the top portion to the bottom portion, the sash slideably engaged with the two jambs between an open configuration wherein the sash is not in contact with either of the top portion or the bottom portion and a closed configuration wherein the sash is in contact with one of: the top portion and the bottom portion; and at least one screen assembly mounted in at least one of: the top portion or the bottom portion, the at least one screen assembly including: a roller assembly substantially hidden from view; and a control bar including a ferromagnetic material; and a screen material attached to the roller assembly, an end of the screen material connected to the control bar, the screen assembly configured to wind the screen material around the roller assembly and to permit the screen material to unwind from the roller assembly under tension applied to move the control bar away from the roller assembly, wherein the control bar automatically attaches to at least one magnet of the sash when the sash is in the closed configuration, wherein the at least one magnet is disposed in the lower rail of the sash when the screen assembly is mounted in the bottom portion, and the at least one magnet is disposed the upper rail of the sash when the screen assembly is mounted in the top portion; and wherein the at least one sash is configured to tilt out of a plane formed by the frame, automatically disengaging the control bar from the at least one magnet of the sash.
12. The fenestration assembly of claim 11, wherein each of the two jambs form first slots extending lengthwise along at least a portion of the jamb between the top portion and the bottom portion, and the control bar extends beyond the sash and into the first slots.
13. The fenestration assembly of claim 12, wherein each of the first slots includes a stop, the stops configured to prevent movement of the control bar beyond the stops and automatically disengage the control bar from the at least one magnet if the sash moves beyond the stops.
14. The fenestration assembly of claim 11, wherein the sash further includes at least one ejector facing the control bar, the at least one ejector moveable between a first position wherein the at least one ejector is at or below the surface of the sash and a second position wherein a portion of the at least one ejector projects beyond the surface of the sash to disengage the control bar from the at least one magnet.
15. The fenestration assembly of claim 14, wherein the sash further includes a ribbon connected to the at least one ejector and configured such that pulling on the ribbon moves the at least one ejector to the second position.
16. The fenestration assembly of claim 11, wherein the at least one magnet is a cylindrical magnet having a longitudinal axis, the cylindrical magnet polarized across its diameter such that rotating the cylindrical magnet about its longitudinal axis varies a magnetic force in a direction of the control bar between a first level of the magnetic force sufficient to engage the control bar and a second level of the magnetic force insufficient to engage the control bar.
17. The fenestration assembly of claim 11, wherein: the at least one sash is a first sash and a second sash; and the at least one screen assembly is a first screen assembly and a second screen assembly, wherein the first screen assembly is mounted in the bottom portion and the second screen assembly is mounted in the top portion.
18. The fenestration assembly of claim 11, wherein the end of the screen material automatically attaches to the at least one sash via the at least one magnet when the at least one sash is closed.
19. The fenestration assembly of claim 11, further comprising an angled rail slope on the at least one sash adjacent to the end of the screen material, the angled rail slope configured to facilitate the disengagement of the end of the screen material from the at least one sash during the tilting of the sash.
20. A screen assembly for a fenestration assembly, the fenestration assembly including a frame and a sash operatively coupled with the frame, the screen assembly comprising: a roller assembly configured to be coupled to the frame such that the roller assembly is substantially hidden from view, the roller assembly including: a tubular member formed of a rigid tube having an inner surface; a damper assembly rotationally fixed to the frame, the damper assembly including a damper positioned within the tubular member; and a fluid in a space between the damper and the inner surface of the tubular member; and a screen material attached to the tubular member such that the roller assembly is operable to tension the screen material to wind the screen material around the tubular member, the damper assembly controlling a rate at which the screen material winds around the tubular member; and a control bar connected to an end of the screen material and including a first magnetic element, the control bar configured to extend beyond the sash and to automatically attach to a second magnetic element of the sash when the sash is closed; and wherein the sash is configured to tilt out of a plane formed by the frame, automatically disengaging the control bar from the second magnetic element of the sash.
21. The screen assembly of claim 20, wherein the damper includes: a central support; and at least one blade extending from the central support.
22. The screen assembly of claim 21, wherein the blade forms a circular cross-section.
23. The screen assembly of claim 20, wherein the damper includes a cylinder.
24. The screen assembly of claim 20, wherein edges of the screen material are configured to extend into slots extending along the frame.
25. The screen assembly of claim 20, wherein the roller assembly further includes: a rod extending through the tubular member and configured to be rotationally fixed to the frame; a coupler attached to an end of the rod within the tubular member, the coupler coupling the damper to the rod; and a bearing attached to the tubular member, the rod extending through the bearing, the tubular member and bearing rotatable about the rod.
26. The screen assembly of claim 25, wherein the damper assembly further includes a fork, the fork configured to engage the coupler to couple the damper to the rod.
27. The screen assembly of claim 25, wherein the roller assembly further includes a spring extending along the rod and connecting the coupler to the bearing to provide a rotational bias to the roller assembly to tension the screen material.
28. The screen assembly of claim 25, wherein the damper assembly further includes at least one radial seal disposed between the fork and the damper and configured to seal against the inner surface of the tubular member.
29. The screen assembly of claim 28, wherein the roller assembly further includes a plug disposed adjacent to an end of the damper assembly opposite the coupler, the plug including: a plug body; and at least one radial seal disposed along the plug body and sealing between the plug body and the inner surface of the tubular member, the fluid substantially filling a space defined by the at least one radial seal disposed between the fork and the damper, the at least one radial seal disposed along the plug body, and the inner surface of the tubular member.
30. The screen assembly of any of claims 20, wherein the fluid has a kinematic viscosity ranging from 5,000 cSt to 500,000 cSt.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments, and together with the description serve to explain the principles of the disclosure.
(2) FIG. 1 is an interior view of a fenestration assembly, according to some embodiments of this disclosure.
(3) FIG. 2 is a cross-sectional view of the fenestration assembly of FIG. 1 showing upper and lower screen assemblies, according to some embodiments of this disclosure.
(4) FIG. 3 is a cross-sectional view of a jamb of the fenestration assembly of FIG. 1, where a lower sash can slideably engage the jamb, according to some embodiments of the disclosure.
(5) FIG. 4 is a cross-sectional view of a jamb of the fenestration assembly of FIG. 1, where an upper sash can slideably engage the jamb, according to some embodiments of the disclosure.
(6) FIGS. 5A and 5B are schematic cross-sectional views of an edge of a screen material of a screen assembly, according to some embodiments of this disclosure.
(7) FIG. 6 is an enlarged schematic cross-sectional view of a portion of the jamb shown in FIG. 3, according to some embodiments of the disclosure.
(8) FIG. 7 is an enlarged schematic cross-sectional view of a portion of the jamb shown in FIG. 3, according to some other embodiments of the disclosure.
(9) FIG. 8 is a schematic side view of a raised feature attached to screen material, according to some embodiments of this disclosure.
(10) FIG. 9 is a schematic perspective view a screen assembly, according to some embodiments of this disclosure.
(11) FIG. 10 is a perspective view of an interior of a roller assembly, according to some embodiments of this disclosure.
(12) FIG. 11 is a perspective cross-sectional view of the roller assembly of FIG. 10 showing a damper assembly of the roller assembly, according to some embodiments of this disclosure.
(13) FIG. 12 is a perspective end view of another damper assembly, according to some embodiments of this disclosure.
(14) FIG. 13 is a perspective end view of another damper assembly, according to some embodiments of this disclosure.
(15) FIG. 14 is a side view of a portion of the fenestration assembly of FIG. 1, showing a screen rethreading system, according to some embodiments of the disclosure.
(16) FIG. 15 is perspective view of the portion of the fenestration assembly shown in FIG. 14, according to some embodiments of the disclosure.
(17) FIG. 16 is a perspective view of a portion of the upper sash of the fenestration assembly of FIG. 1 including a check rail seal, according to some embodiments of the disclosure.
(18) FIG. 17 is a side perspective view of the check rail seal of FIG. 16, according to embodiments of the disclosure.
(19) FIG. 18 is a side view of another portion of one of the jambs of the fenestration assembly of FIG. 1, according to some embodiments of the disclosure.
(20) FIG. 19 is a cross-sectional view of the portion of the jamb shown in FIG. 18.
(21) FIG. 20 is a partial perspective view of a portion of the fenestration assembly of FIG. 1, according to some embodiments of the disclosure.
(22) FIGS. 21A and 21B are schematic cross-sectional views of the lower rail including the magnet of FIG. 1, according to some embodiments of this disclosure.
(23) FIGS. 22A and 22B are cross-sectional views of a jamb of the fenestration assembly of FIG. 1, where a lower sash can slideably engage the jamb, according to some embodiments of the disclosure.
(24) FIGS. 23A and 23B are cross-sectional views of a jamb of the fenestration assembly of FIG. 1, where an upper sash can slideably engage the jamb, according to some embodiments of the disclosure.
(25) FIGS. 24A and 24B are perspective views of a screen release mechanism, according to some embodiments of this disclosure.
(26) FIGS. 25A and 25B are cross-sectional views of a portion of another fenestration assembly, according to some embodiments of this disclosure.
(27) FIGS. 26A and 26B are cross-sectional views of another magnet and portion of a screen assembly, according to some embodiments of this disclosure.
(28) Persons skilled in the art will readily appreciate that various aspects of the present disclosure can be realized by any number of methods and apparatus configured to perform the intended functions. It should also be noted that the accompanying drawing figures referred to herein are not necessarily drawn to scale, but may be exaggerated to illustrate various aspects of the present disclosure, and in that regard, the drawing figures should not be construed as limiting.
DETAILED DESCRIPTION
(29) Some inventive concepts provided by this disclosure relate to edge retention features, enhanced roller assembling dampening designs, improved screen-to-sash coupling mechanisms, more reliable screen winding features, and/or enhanced bug sealing between sashes, for example. These inventive concepts are examples only, and further inventive concepts, as well as their advantages and associated functions will be appreciated from this disclosure.
(30) This disclosure is not meant to be read in a restrictive manner. For example, the terminology used in the application should be read broadly in the context of the meaning those in the field would attribute such terminology.
(31) With respect terminology of inexactitude, the terms “about” and “approximately” may be used, interchangeably, to refer to a measurement that includes the stated measurement and that also includes any measurements that are reasonably close to the stated measurement. Measurements that are reasonably close to the stated measurement deviate from the stated measurement by a reasonably small amount as understood and readily ascertained by individuals having ordinary skill in the relevant arts. Such deviations may be attributable to measurement error or minor adjustments made to optimize performance, for example. In the event it is determined that individuals having ordinary skill in the relevant arts would not readily ascertain values for such reasonably small differences, the terms “about” and “approximately” can be understood to mean plus or minus 10% of the stated value.
(32) Certain terminology is used herein for convenience only. For example, words such as “top”, “bottom”, “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configuration shown in the figures or the orientation of a part in the installed position. Indeed, the referenced components may be oriented in any direction. Similarly, throughout this disclosure, where a process or method is shown or described, the method may be performed in any order or simultaneously, unless it is clear from the context that the method depends on certain actions being performed first.
(33) As used herein, the phrase “within any range defined between any two of the foregoing values” literally means that any range may be selected from any two of the values listed prior to such phrase regardless of whether the values are in the lower part of the listing or in the higher part of the listing. For example, a pair of values may be selected from two lower values, two higher values, or a lower value and a higher value.
(34) FIG. 1 is an interior view of a fenestration assembly 10, according to some embodiments of this disclosure. As shown, the fenestration assembly 10 is a double-hung window that includes a frame 12, an upper sash 14, and a lower sash 16. The frame 12 can include a top portion, or head 18, a bottom portion, or sill 20, and jambs 22. Together, the head 18, the sill 20, and the jambs 22 surround and support the upper sash 14 and the lower sash 16. The upper sash 14 can include an upper rail 24, a lower rail 26, stiles 28, and window pane 30. Together, the upper rail 24, the lower rail 26, and the stiles 28 surround and support the window pane 30. The lower sash 16 can include an upper rail 32, a lower rail 34, stiles 36, and window pane 38. Together, the upper rail 32, the lower rail 34, and the stiles 36 surround and support the window pane 38.
(35) As shown in FIG. 1, fenestration assembly 10 includes an upper screen assembly 40, a lower screen assembly 42, and a check rail seal 44. The upper screen assembly 40 can extend between the head 18 and the upper rail 24 of the upper sash 14. The lower screen assembly 42 can extend between the sill 20 and the lower rail 34 of the lower sash 16. In FIG. 1, the upper sash 14 and the lower sash 16 are both shown in open configurations. That is, the upper sash 14 is not in contact with the head 18 and the lower sash 16 is not in contact with the sill 20.
(36) FIG. 2 is a cross-sectional view of the fenestration assembly 10 of FIG. 1 showing the upper screen assembly 40, the lower screen assembly 42, and the check rail seal 44, according to some embodiments of this disclosure. As shown in FIG. 2, the upper screen assembly 40 can include a roller assembly 46, a screen material 48 having an end 50, and a control bar 52. In some embodiments, the screen material 48 can be a fiberglass mesh coated with polyvinyl chloride. In some embodiments, the control bar 52 can be a ferromagnetic material which can be attached to the upper rail 24 by an attraction of a magnet 54 attached to the upper rail 24. The control bar 52 can be attached to the end 50 of the screen material 48, thus connecting the end 50 of the screen material 48 to the upper sash 14. Another end (not shown) of the screen material 48 opposite end 50 can be attached to the roller assembly 46. The roller assembly 46 can be rotationally biased to cause the screen material 48 to coil, wind or roll up, around the roller assembly 46 until tension provided by the connection of the end 50 to the upper sash 14 prevents further winding about the roller assembly 46. The tension can draw the screen material 48 taut as it extends between the roller assembly 46 and the upper rail 24 of the upper sash 14, as shown in FIG. 2.
(37) The control bar 52 can include any material that is ferromagnetic at room temperature. In some embodiments, the control bar 52 can include iron, nickel, cobalt, or ferromagnetic alloys including any of iron, nickel, and/or cobalt. In some embodiments, the control bar 52 can include a martensitic or ferritic stainless steel. In some embodiments, the control bar 52 can include type 416 stainless steel. In some embodiments, the control bar 52 can consist of type 416 stainless steel, or be entirely formed of type 416 stainless steel.
(38) In use, as additional tension is applied to the end 50 of the screen material 48 by moving the upper sash 14 away from the roller assembly 46, the screen material 48 unwinds from the roller assembly 46 against the rotational bias. Conversely, as the tension applied to the end 50 of the screen material 48 is reduced by moving the upper sash 14 toward the roller assembly 46, the rotational bias of the roller assembly 46 winds the screen material 48 around the roller assembly 46. The upper sash 14 can be moved vertically within the frame 12 to open or close an area of the fenestration assembly 10 and extend or retract the screen material 48. The upper sash 14 can be moved fully upward to be in contact with the head 18 in a closed configuration, closing the area of fenestration assembly 10 between the upper sash 14 and the head 18 and retracting the screen material 48 into the roller assembly 46. In the closed configuration, the screen material 48 does not obscure the view through the window pane 30. Also, the retracted screen material 48 is protected from the elements when not in use, reducing the opportunity for the accumulation of detritus on the screen material 48. In the open configuration, the screen material 48 does not cover the upper sash 14, unlike a conventional full screen, which provides for an improved aesthetic appearance of the fenestration assembly 10.
(39) As shown in FIG. 2, in some embodiments, the head 18 can include a head cover 56 and head seal 57. The head cover 56 hides the upper screen assembly 40, including the roller assembly 46 and any of the screen material 48 wound about the roller assembly 46, from view for a more aesthetically pleasing appearance. So configured, the roller assembly 46 and any of the screen material 48 wound about the roller assembly 46 are substantially hidden from view. That is, the roller assembly 46 and any of the screen material 48 wound about the roller assembly 46 are not observable by passersby. The head seal 57 can seal against the upper rail 24 when the upper sash 14 is moved fully upward to be in contact with the head 18.
(40) As also shown in FIG. 2, the lower screen assembly 42 can include a roller assembly 58, a screen material 60 having an end 62, and a control bar 64. The screen material 60 and the control bar 64 can include substantially similar features to those described above for the screen material 48 and the control bar 52. As with the control bar 52, the control bar 64 can be attached to the lower rail 34 by an attraction of a magnet 66 attached to the lower rail 34. The control bar 64 can be attached to the end 62 of the screen material 60, thus connecting the end 62 to the lower sash 16. Another end (not shown) of the screen material 60 opposite end 62 can be attached to the roller assembly 58. The roller assembly 58 can be rotationally biased to cause the screen material 60 to coil, wind or roll up, around the roller assembly 58 until tension provided by the connection of the end 62 to the lower sash 16 prevents further winding about the roller assembly 58. The tension can draw the screen material 60 taut as it extends between the roller assembly 58 and the lower rail 34 of the lower sash 16, as shown in FIG. 2.
(41) In use, as additional tension is applied to the end 62 of the screen material 60 by moving the lower sash 16 away from the roller assembly 58, the screen material 60 unwinds from the roller assembly 58 against the rotational bias. Conversely, as the tension applied to the end 62 of the screen material 60 is reduced by moving the lower sash 16 toward the roller assembly 58, the rotational bias of the roller assembly 58 winds the screen material 60 around the roller assembly 58. The lower sash 16 can be moved vertically within the frame 12 to open or close another area of the fenestration assembly 10 and extend or retract the screen material 60. The lower sash 16 can be moved fully downward to be in contact with the sill 20 in a closed configuration, closing the area of fenestration assembly 10 between the lower sash 16 and the sill 20 and retracting the screen material 60 into the roller assembly 58. In the closed configuration, the screen material 60 does not obscure the view through the window pane 38. Also, the retracted screen material 60 is protected from the elements when not in use, reducing the opportunity for the accumulation of detritus on the screen material 60. In the open configuration, the screen material 60 does not cover the lower sash 16, unlike a conventional full screen, which provides for an improved aesthetic appearance of the fenestration assembly 10. As shown in FIG. 2, the lower rail 34 can further include a sill seal 67. The sill seal 67 can seal against the sill 20 when the lower sash 16 is moved fully downward to be in contact with the sill 20.
(42) As shown in FIG. 2, the sill 20 can include a upper sill cover 68, a lower sill cover 69, and a sill cover receptor 70. The upper sill cover 68 and the lower sill cover 69 hide the lower screen assembly 42, including the roller assembly 58 and any of the screen material 60 wound about the roller assembly 58, from view for a more aesthetically pleasing appearance. So configured, the roller assembly 58 and any of the screen material 60 wound about the roller assembly 58 are substantially hidden from view. That is, the roller assembly 58 and any of the screen material 60 wound about the roller assembly 58 are not observable by passersby. The sill cover receptor 70 provides a structural attachment for the lower sill cover 69. The upper sill cover 68, the lower sill cover 69, and the sill cover receptor 70 are more clearly shown in FIGS. 25A and 25B.
(43) In some embodiments, the lower screen assembly 42 can be removed from the fenestration assembly 10 by raising the lower sash 16, detaching the control bar 64 from the magnet 66 to permit the screen material 60 to retract into the lower screen assembly 42, removing the lower sill cover 69 from the sill cover receptor 70, and removing the sill cover receptor 70 from the sill 20. Then the lower screen assembly 42 can be removed from the sill 20 and a repaired or replacement lower screen assembly 42 installed by reversing the process. A similar process may be applied to replace the upper screen assembly 40, without the need to remove or replace the head cover 56.
(44) In some embodiments, the check rail seal 44 can extend from the lower rail 26 of the upper sash 14 to the lower sash 16, as shown in FIG. 2. In other embodiments, the check rail seal 44 can extend from the upper rail 32 to the upper sash 14. The check rail seal 44 is described in further detail below with reference to FIGS. 16-17. Together, the upper screen assembly 40, the upper sash 14, the check rail seal 44, the lower sash 16, and the lower screen assembly 42 can provide a substantially continuous vertical barrier to insects and other pests as the upper sash 14 and the lower sash 16 slideably engage with the frame 12.
(45) Although the fenestration assembly 10 is shown and described with two screen assemblies, upper screen assembly 40 and lower screen assembly 42, various embodiments include fenestration assemblies having only one screen assembly, or more than two screen assemblies.
(46) FIG. 3 is a cross-sectional view of one of the jambs 22 where the lower sash 16 can slideably engage the jambs 22, according to some embodiments of the disclosure. In FIG. 3, a portion of the screen material 60 has been unwound from the roller assembly 58 of the lower screen assembly 42 by moving the lower sash 16 away from the sill 20, as shown in FIGS. 1 and 2. As shown in FIG. 3, each of the jambs 22 include a first slot 71 formed by the jamb 22. Although only one of the two jambs 22 is shown in FIG. 3 for ease of illustration, it is understood that each of the jambs 22 includes a first slot 71, thus, fenestration assembly 10 includes two first slots 71. The screen material 60 is wider than the lower sash 16 so that edges 72 (one shown in FIG. 3) of the screen material 60 can project into the first slots 71 of each of the two jambs 22 when unwound from the roller assembly 58. Thus, together the screen material 60 and the jambs 22 can provide a substantially continuous horizontal barrier to insects and other pests.
(47) FIG. 4 is a cross-sectional view of one of the jambs 22 where the upper sash 14 can slideably engage the jambs 22, according to some embodiments of the disclosure. In FIG. 4, a portion of the screen material 48 has been unwound, or unwound from the roller assembly 46 of the upper screen assembly 40 by moving the upper sash 14 away from the head 18, as shown in FIGS. 1 and 2. As shown in FIG. 4, each of the jambs 22 include a second slot 74 formed by the jamb 22. Although only one of the two jambs 22 is shown in FIG. 4 for ease of illustration, it is understood that each of the jambs 22 includes a second slot 74, thus, fenestration assembly 10 includes two second slots 74. The screen material 48 is wider than the upper sash 14 so that edges 76 (one shown in FIG. 4) of the screen material 48 can project into the second slots 74 of each of the two jambs 22 when unwound from the roller assembly 46. Thus, together the screen material 48 and the jambs 22 can provide a substantially continuous horizontal barrier to insects and other pests.
(48) Referring back to FIG. 3, in use, as the screen material 60 repeatedly moves along the first slots 71 over time, the edges 72 may be subjected to frictional forces that can cause fraying and damage to the screen material 60, compromising its effectiveness as a barrier to insects and pests and making the screen material 60 less aesthetically pleasing. In some embodiments, the edges 72 can be formed to strengthen its resistance to fraying and damage. FIGS. 5A and 5B are schematic cross-sectional views of one of the edges 72 of the screen material 60, according to some embodiments of this disclosure. The screen material 60 can be folded, as shown in FIG. 5A, and then the folded screen material 60 can be fused together to form the edge 72. The screen material 60 can include a single fold or a plurality of folds as desired. In some embodiments, the fusing process can include applying heated plates to the folded screen material 60. In some embodiments, the fusing process can include ultrasonically welding, heat welding and/or applying an adhesive to the folded screen material 60.
(49) In the embodiment shown in FIGS. 5A and 5B, there are 5 folds in the material. In some embodiments, the edge 72 can include as few as 1 fold, or 2 folds, or as many as 3 folds, 4 folds, 5 folds or more. The greater the number of folds, the stronger and more damage resistant the edge 72 can become. However, the greater the number of folds, the thicker the edge 72 becomes, increasing the size of the lower screen assembly 42. A larger lower screen assembly 42 is more difficult to hide in the sill 20. In embodiments having only a single fold, the fused edge 72 can have a thickness comparable to the unfolded screen material 60 as fibers of the mesh of one half of the fold move into the gaps between the fibers of the mesh of the other half of the fold during the fusing process. Such a single-fold edge can still have greater resistance to fraying and damage as compared with the screen material 60 without increasing the size of the lower screen assembly 42. Thus, in some embodiments, the single-fold edge has approximately the same thickness as a remainder of the screen material 60.
(50) Although FIGS. 5A and 5B describe the edge 72 of the screen material 60 of the lower screen assembly 42, it is understood that the same description can be applied to the edge 76 of the screen material 48 of the upper screen assembly 40.
(51) FIG. 6 is a schematic cross-sectional view of a portion of the jamb 22 shown in FIG. 3, according to some embodiments of the disclosure. As shown in FIG. 6, the lower screen assembly 42 can further include a plurality of raised features including a flat hook 78. At least one flat hook 78 can be attached to, and extend along a portion of, each of the edges 72 (one shown in FIG. 6). In some embodiments, the flat hooks 78 can be flexible hooks that can wind up around the roller assembly 58 along with the screen material 60. In some embodiments, the flat hooks 78 can be formed of a thin sheet of a flexible polymer including, for example, polyvinyl chloride, polyester, or polypropylene. The flat hooks 78 can be attached to the edges 72 by, for example, ultrasonic welding, heat welding or an adhesive. The flat hooks 78 can extend along the portion of each of the edges 72 adjacent to the end 62 (FIG. 2) of the screen material 60. In some embodiments, each of the flat hooks 78 can extend along the edge 72 for as little as 0.25 inches (6.3 mm), 0.5 inches (12.7 mm), 0.75 inches (19.1 mm), or a much as 1.25 inches (31.8 mm), 1.5 inches (38.1 mm), or 2 inches (50.1 mm), or for any length between any of the preceding lengths. In some embodiments, the flat hook 78 may extend along the edge 72 for 1 inch (25.4 mm).
(52) As further shown in FIG. 6, each of the first slots 71 can further include a screen edge retention feature 80 attached to the jamb 22 and extending along a portion of each of the first slots 71. The screen edge retention features 80 can be, for example, in the form of a complementary raised structure or flat hook configured to engage the flat hook 78 and retain the edges 72 at least partially within the first slots 71, as shown in FIG. 6. In some embodiments, the screen edge retention features 80 can be formed of a thin sheet including for example, polycarbonate or polyvinyl chloride. Together, the flat hooks 78 and the screen edge retention features 80 can keep the edges 72 of the screen material 60 within the first slots 71 to preserve the substantially continuous horizontal barrier to insects and other pests. In some embodiments, the screen edge retention features 80 do not extend along a portion of the first slots 71 adjacent to the sill 20. This gap in the screen edge retention features 80 frees the flat hooks 78 from the first slots 71 when the screen material 60 is fully wound up, or retracted, by the roller assembly 58, allowing the lower screen assembly 42 to be more easily removed from the sill 20 for repair or replacement.
(53) As further shown in FIG. 6, each of the first slots 71 can further include strips of low friction material 82 attached to the jamb 22 and extending along each of the first slots 71 to reduce the friction damage to the edges 72 and provide for smoother operation of the lower screen assembly 42. In some embodiments, the low friction material 82 can include polyvinyl chloride, polytetrafluoroethylene, or polypropylene, for example, although a variety of materials are contemplated.
(54) FIG. 7 is a schematic cross-sectional view of a portion of the jamb 22 shown in FIG. 3, according to some other embodiments of the disclosure. In particular, FIG. 7 shows an alternative arrangement for retaining the edges of the screen material 60 in the jambs 22. As shown in FIG. 7, the lower screen assembly 42 can further include a plurality of raised features including a flexible strip 84. At least one flexible strip 84 can be attached to, and extend along a portion of, each of the edges 72 (one shown in FIG. 7). In some embodiments, the flexible strip 84 can include a flexible polymer, such as polyvinyl chloride, polypropylene, or polyester, for example, attached to the edges 72 by ultrasonic welding, heat welding, and/or an adhesive, for example. In some embodiments, the flexible strip 84 can include a thin sheet of metal attached to the edges 72 by an adhesive or a physical crimping of the metal. In some embodiments, the flexible strips 84 can extend along the portion of each of the edges 72 adjacent to the end 62 (FIG. 2) of the screen material 60. In some embodiments, the flexible strips 84 extend along the edge 72 for as little as 0.5 inches (12.7 mm), 0.75 inches (19.1 mm), 1 inch (25.4 mm), or a much as 1.5 inches (38.1 mm), 2 inches (50.1 mm), 2.5 inches (63.5 mm), or 3 inches (76.2 mm), or for any length between any of the preceding lengths. In some embodiments, the flat hook 78 may extend along the edge 72 for 1.25 inches (31.8 mm), for example, although a variety of dimensions are contemplated.
(55) As shown in FIG. 7, each of the first slots 71 can further include a screen edge retention feature 86 extending along a portion of each of the first slots 71. The screen edge retention features 86 can be, for example, in the form of a complementary raised structure configured to block movement of the flexible strip 84 out of the first slot 71. By engaging the flexible strip 84 in this manner, the screen edge retention feature 86 can retain the edge 72 at least partially within the first slot 71. In some embodiments, the screen edge retention feature 86 can be a rigid structure including a polymer, such as polyvinyl chloride, polyethylene, or polycarbonate, for example. In some embodiments, each of the first slots 71 can further include a low friction material strip 88, such as a weather stripping, that extends along each of the first slots 71 opposite the screen edge retention feature 86. The low friction material strip 88 can include a resilient portion 90 extending toward the screen material 60. The resilient portion 90 can help prevent the flexible strip 84 from moving past the screen edge retention feature 86 by forcing the screen material toward the screen edge retention feature 86. Together, the flexible strips 84, the low friction material strip 88, and the screen edge retention features 86 can keep the edges 72 of the screen material 60 within the first slots 71 to preserve the substantially continuous horizontal barrier to insects and other pests. In some embodiments, the screen edge retention features 86 do not extend along a portion of the first slots 71 adjacent to the sill 20. This gap in the screen edge retention features 86 frees the flexible strips 84 from the first slots 71 when the screen material 60 is fully wound up, or retracted, by the roller assembly 58, allowing the lower screen assembly 42 to be more easily removed from the sill 20 for repair or replacement.
(56) FIG. 8 is a schematic side view of the flexible strip 84 attached to the screen material 60, according to some embodiments of this disclosure. As shown in FIG. 8, the flexible strip 84 can include two ends 92. In the view of FIG. 8, the two ends 92 are oriented opposite one another along the length of the screen material 60 (e.g., along the height of the screen material in the foregoing examples). The flexible strip 84 can be attached to the screen material 60 at the two ends 92 but remain unattached to the screen material 60 between the two ends 92. A length of the flexible strip 84 is greater than a distance between the two ends 92 when attached to the screen material 60 so that a portion of the flexible strip 84 between the ends 92 raises up from the screen material 60 and forms a raised hump 94, also described as a raised portion 94. The raised hump, or raised portion generally projects in either a direction of the interior or exterior of the fenestration unit 10. The raised hump 94 can be most pronounced when the screen material 60 is unwound from the roller assembly 58 and in tension, as shown in FIG. 8. When the screen material 60 including the flexible strip 84 is wound about the roller assembly 58, the raised hump 94 can be less pronounced. In some embodiments when the screen material 60 including the flexible strip 84 is wound about the roller assembly 58, the entire length of the flexible strip 84 can lay against the screen material 60, substantially eliminating the raised hump 94. This feature of collapsing the raised hump 94 is a feature of the screen material 60 being wrapped around a circumference of the tubular member 96. Such embodiments can provide a plurality of raised features attached to the edges 72 without substantially increasing the size of the lower screen assembly 42 (e.g., due to the nature of the raised hump 94, or raised portion 94 collapsing upon winding of the screen material 60).
(57) FIG. 9 is a schematic perspective view of the lower screen assembly 42, according to some embodiments of this disclosure. FIG. 9 shows the lower screen assembly 42 uninstalled from the sill 20 with a portion of the screen material 60 rolled up around the roller assembly 58, and a portion of the screen material 60 extending from the roller assembly 58. As shown in FIG. 9, the roller assembly 58 can include a tubular member 96, a rod 98, at least one pin 100 (two shown), and a bearing 102. The tubular member 96 can be a hollow, rigid tube as shown further in FIGS. 10 and 11 described below. The tubular member 96 can be formed of metal or a rigid polymer, for example. The rod 98 and the pins 100 can be formed of rigid materials. The pins 100 can extend from an end of the rod 98 at least partially perpendicular to the rod 98. In the embodiment shown in FIG. 9, the pins 100 extend perpendicularly from the end of the rod 98. The bearing 102 can include a polymer, such as polyvinyl chloride, polypropylene, or any of a variety of other materials.
(58) The tubular member 96 can be attached to the bearing 102. The rod 98 can extend through the bearing 102 and into the tubular member 96. The rod 98 is not fixed with respect to the bearing 102, so that the bearing 102 and the tubular member 96 can rotate about the rod 98. When the lower screen assembly 42 is installed in the sill 20, the pins 100 engage corresponding features (not shown) in one of the jambs 22 to prevent rotation of the rod 98, while the bearing 102 permits rotation of the tubular member 96 about the rod 98 to allow the screen material 60 to extend and retract as described above.
(59) FIG. 10 is a perspective view of an interior of the roller assembly 58, according to some embodiments of this disclosure. As shown in FIG. 10, the roller assembly 58 can further include a coupler 104, a spring 106, a damper assembly 108, and a plug 110. The plug 110 can include a plug body 112 and at least one radial seal 114 (two shown). The radial seal 114 may be any type of radial seal known in the art, such as an O-ring, for example. The damper assembly 108 can include a damper 116, a fork 118, and at least one radial seal 120 (one shown). In some embodiments, the spring 106 can be a helical spring, as shown in FIG. 10. In some embodiments, the coupler 104, the plug 110, the damper 116, and the fork 118 can be formed of rigid materials. The radial seals 114 and radial seal 120 can be formed of any of a number of elastomeric polymers known in the art.
(60) The spring 106 connects to the coupler 104 and extends along the length of the rod 98 to connect to the bearing 102 (FIG. 9). Thus, the spring 106 acts between the non-rotating rod 98 and the tubular member 96 to provide the rotational bias to the roller assembly 58, as described above. The coupler 104 is attached to an end of the rod 98 within the tubular member 96. The coupler 104 is configured to couple to the fork 118 to attach the damper assembly 108 to the rod 98. The radial seal 120 is disposed between the fork 118 and the damper 116 and seals between the damper assembly 108 and an inner surface 122 of the tubular member 96. The plug 110 is disposed adjacent to an end of the damper assembly 108 opposite the coupler 104. The plug 110 is not rotationally fixed with respect to the damper assembly 108. The radial seals 114 are disposed along the plug body 112 and seal between the plug body 112 and the inner surface 122 of the tubular member 96.
(61) A fluid 124 can substantially fill a space defined by the radial seals 114, the radial seal 120, and the inner surface 122 of the tubular member 96. The fluid 124 can be a fluid having a kinematic viscosity as low as 5,000 centistoke (cSt), 10,000 cSt, 20,000 cSt, 30,000 cSt, 40,000 cSt, or 50,000, or as high as 60,000 cSt, 70,000 cSt, 80,000 cSt, 90,000 cSt, 100,000 cSt, 250,000 cSt, or 500,000 cSt or within any range defined between any two of the foregoing values. For example, in some embodiments, the kinematic viscosity of the fluid 124 can range from 5,000 cSt to 500,000 cSt, 10,000 cSt to 250,000 cSt, 20,000 cSt, to 100,000 cSt, 30,000 cSt to 90,000 cSt, 40,000 cSt to 80,000 cSt, or 50,000 cSt to 70,000 cSt, for example, although a variety of values are contemplated.
(62) In terms of operation, the damper assembly generally operates to reduce the rotational velocity at which the screen material is retracted. FIG. 11 is a perspective cross-sectional view of the roller assembly 58 of FIG. 10, according to some embodiments of this disclosure taken along line 11-11 in FIG. 10. FIG. 11 shows the damper 116 disposed within the tubular member 96. As shown in the embodiment of FIG. 11, the damper 116 can include at least one blade 126 (four shown) extending from a central support 128. The fluid 124 substantially fills the space between the blades 126 and the central support 128, and the inner surface 122 of the tubular member 96, including a gap between outer surfaces 129 of the blades 126 and the inner surface 122.
(63) Considering FIGS. 9-11 together, in use, as a portion of the screen material 60 is unwound from the roller assembly 58 of the lower screen assembly 42 by moving the lower sash 16 away from the sill 20 as described above in reference to FIG. 3, the tubular member 96, which is attached to the screen material 60, rotates about the non-rotating rod 98, winding up the spring 106, increasing its rotational bias. If the control bar 64 is suddenly released from the lower sash 16, the damper assembly 108 can provide a counter-force to the rotational bias of the spring 106 to limit the rotational speed of the tubular member 96. Without the damper assembly 108, the spring 106 could rotate the tubular member 96 so quickly that the lower screen assembly 42, or other parts of the fenestration assembly 10, could be damaged or a user could be harmed, for example.
(64) The counter-force can be directly related to the rotational speed of the tubular member 96, thus limiting the rotational speed of the tubular member 96 without significantly impeding the rotation of the tubular member 96 at lower rotational speeds, such as during normal operation of the lower sash 16. Without wishing to be bound by any theory, it is believed that the rotation between the tubular member 96 and the damper 116 creates shear forces in the fluid 124 between the inner surface 122 of the tubular member 96 and the outer surfaces 129 of the blades 126 that are directly related to the rotational speed of the tubular member 96, thus providing a damping force to resist the built-up rotational bias in the spring 106 at higher rotational speeds.
(65) Tubular member 96 is both the tube around which the screen material 60 winds and the tube providing the inner surface 122 against which the shear forces in the fluid 124 are created to counter the rotational bias of the spring 106. Use of the same tube for both purposes may provide for a more efficient (e.g., relatively more compact) lower screen assembly 42.
(66) Although the damper 116 is shown in FIG. 11 with four blades 126 extending from the central support 128 and forming two arc-shaped structures in cross-section, it is understood that embodiments of the disclosure may more blades or fewer blades, and may include blades forming other shaped structures. Embodiments of the damper 116 may include a single blade forming a single structure in cross-section, such as a circular cross-section forming a cylinder. In some embodiments, the damper 116 may not include a central support 128 as the single structure, such as a cylindrical structure, may provide sufficient support for the damper 116.
(67) FIG. 12 is a perspective end view of another damper assembly, according to some embodiments of this disclosure. FIG. 12 shows a damper assembly 130. The damper assembly 130 can be used in place of the damper assembly 108 described above in reference to FIGS. 10 and 11. The damper assembly 130 can include a damper 132, a fork 134, and at least one radial seal 136 (two shown). The damper 132 can include at least one blade 138 (eight shown) extending from a central support 140. In use, the fork 134 can couple to the coupler 104 (FIG. 10) to attach the damper assembly 130 to the rod 98. As with the damper assembly 108, the damper assembly 130 can provide a counter-force to the rotational bias of the spring 106 to limit the rotational speed of the tubular member 96.
(68) In some embodiments, the damper 132 and the fork 134 are formed from as a single monolithic structure. In other embodiments, the damper 132 and the fork 134 are formed separately, and then joined together by, for example, a threaded connector or connection. In some embodiments, the depositing of the at least one radial seal 136 between the fork 134 and the damper 132 can be less damaging to the at least one radial seal 136 when the damper 132 and the fork 134 are formed separately, and the at least one radial seal 136 is attached before the damper 132 and the fork 134 are joined together.
(69) FIG. 13 is a perspective end view of yet another damper assembly 142, according to some embodiments of this disclosure. The damper assembly 142 can be used in place of the damper assembly 108 described above with reference to FIGS. 10 and 11. The damper assembly 142 can include a damper 143, a fork 144, and at least one radial seal 146 (one shown). The damper 143 can include at least one blade 148 (four shown) extending from a central support 150. In use, the fork 144 can couple to the coupler 104 (FIG. 10) to attach the damper assembly 142 to the rod 98. As with the damper assembly 108, the damper assembly 142 can provide a counter-force to the rotational bias of the spring 106 to limit the rotational speed of the tubular member 96.
(70) In some embodiments, the damper 143 and the fork 144 are formed as a single monolithic structure. In other embodiments, the damper 143 and the fork 144 are formed separately, and then joined together by, for example, a threaded connector or connection. It may be less damaging to the radial seal(s) 146 when the damper 143 and the fork 144 are formed separately, and the at least one radial seal 146 is attached before the damper 143 and the fork 144 are joined together.
(71) Although the embodiments of FIGS. 6-13 are shown and described with respect to the lower screen assembly 42 it is understood that the same description can be applied to the upper screen assembly 40.
(72) As described above in reference to FIGS. 6 and 7, the edges 72 of the screen material 60 can be held within the first slot 71 by the engagement of the plurality of edge retention features, such as flat hooks 78 or flexible strips 84, with the screen retention features, such as screen retention features 80 or 86. However, at a high enough wind speed flowing through the screen material 60, the force against the screen material 60 can be sufficient to disengage the edge retention features from the screen retention features and pull one or both of the edges 72 from the first slots 71. In such a case, the screen material 60 must be rethreaded into the first slot 71 before it is retracted onto the roller assembly 58, or the screen material 60 may fold in upon itself, causing permanent creases on the screen material 60 and/or preventing the roller assembly 58 from retracting the full length of the screen material 60. This problem may be exacerbated by the continued flow of wind through the screen material 60 as the lower sash 16 is closed.
(73) FIGS. 14 and 15 are views of a portion of one of the jambs 22 of the fenestration assembly 10 of FIG. 1, including a screen rethreading system, according to some embodiments of the disclosure. FIG. 14 is a side view from inside the frame 12 and FIG. 15 is a perspective view from outside the frame 12. As shown in the embodiment of FIGS. 14 and 15, the jamb 22 can include a rethreading slot 152 and the first slot 71 can include a chamfered portion 154, a transition portion 156, and a remainder portion 158. The rethreading slot 152 can be disposed at an end of the jamb 22 adjacent to the sill 20 at an interior-facing surface I of the jamb 22. The rethreading slot 152 can extend into the jamb 22 to a depth D sufficient for the rethreading slots 152 of the two jambs 22 together to accommodate the full width of the screen material 60, including edges 72. The chamfered portion 154 can be disposed at an end of the first slot 71 adjacent to the sill 20. The chamfered portion 154 can be formed by a side of the first slot 71 nearest the interior-facing surface I of the jamb 22. The transition portion 156 is disposed between the chamfered portion 154 and the remainder portion 158. The remainder portion 158 can be a balance of the first slot 71 that does not include the chamfered portion 154 and the transition portion 156. In some embodiments, transition portion 156 can include a surface curvature that blends the chamfered portion 154 with the remainder portion 158, or otherwise provides a smooth transition from the narrower width of the slot to the expanded width of the chamfered portion 154. For example, in some embodiments, the chamfered portion 154 and the transition portion 156 together can be in the shape of a so called “lark's tongue chamfer”, as shown best in FIG. 14.
(74) In use, should a high wind force a portion of the edges 72 and a portion of the screen material 60 out of the first slot 71, the portion of the screen material 60 will rethread through the rethreading slot 152 as the lower sash 16 is lowered and the roller assembly 58 retracts the screen material 60 through the rethreading slot 152. However, the control bar 64 can be wider than the lower sash 16 so that it can project into the first slots 71 of each of the two jambs 22. A portion of the screen material 60 adjacent to the control bar 64 cannot move out of the first slot 71 and rethread through the rethreading slot 152 because it is held in the first slot 71 by the control bar 64. Thus, as the lower sash 16 gets close to the sill 20 (e.g., about 4 inches), a tension may develop between a portion of the screen material 60 outside of the first slot 71 and a portion of the screen material 60 close to the control bar 64, which may cause intervening screen material 60 to wrap around a portion of the jamb 22 above the rethreading slot 152. This tension is reduced by the chamfered portion 154, which eliminates a right-angle corner and widens the first slot 71. The transition portion 156 provides a smooth transition between the chamfered portion 154 and the remainder portion 158, reducing the risk of damage to the screen material 60 from an otherwise sharp edge as it passes from the chamfered portion 154 to the remainder portion 158. Without the chamfered portion 154 and the transition portion 156, the screen material 60 wrapped around the jamb 22 may pinch together as it retracted on the roller assembly 58, causing permanent creases on the screen material 60 and/or preventing the roller assembly 58 from retracting the full length of the screen material 60. With the rethreading slot 152, the chamfered portion 154, and the transition portion 156, the screen material 60 may be automatically rethreaded into the first slot 71 and fully retracted onto the roller assembly 58 without damage to the screen material 60 by lowering the lower sash 16.
(75) If a height H of the rethreading slot 152 is great enough, such as greater than 1.5 inches, for example, then the tension on the intervening screen material 60 may be low enough that the screen material 60 may recover from being pinched together before being retracted by the roller assembly 58, or the intervening screen material 60 may not be pinched together at all, without the chamfered portion 154 or the transition portion 156. However, it is desirable for aesthetic purposes to maintain the height H of the rethreading slot 152 as small as possible.
(76) The height H of the rethreading slot 152 may be as small as 0.1 inches, 0.2 inches, 0.4 inches, or 0.6 inches, or as great as 0.8 inches, 1.0 inches, 1.2 inches, or 1.4 inches, for example, or may be within any range defined between any two of the foregoing values, such as 0.1 to 1.4 inches, 0.2 to 1.2 inches, 0.4 to 1.0 inches, 0.6 to 0.8 inches, 0.1 to 0.2 inches, or 0.8 to 1.4 inches, for example. In some embodiments, the height H of the rethreading slot 152 may be 1.5 inches or less, although any of a variety of dimensions are contemplated.
(77) In some embodiments, as shown in FIGS. 14 and 15, the resilient portion 90 of the low friction material strip 88 may not extend beyond an end 160 of the of the screen edge retention feature 86. The end 160 is an end of the screen edge retention feature 86 closest to the sill 20. Thus, the resilient portion 90 may not be opposite the chamfered portion 154 and the transition portion 156 to prevent the resilient portion 90 from pushing against the screen material 60 which may otherwise increase the tension on the screen material 60 an interfere with the retraction of the screen material 60 by the roller assembly 58.
(78) As further shown in FIGS. 14 and 15, in some embodiments, the first slot 71 may further include a bump 162 projecting into the first slot 71 adjacent to the end 160 of the screen edge retention feature 86. The end 160 can be somewhat abrasive to the screen material 60, particularly as the lower sash 16 is raised and the screen material 60 moves past the end 160. In some embodiments, the bump 162 may have a smooth, convex cross-sectional profile, as shown in FIG. 14. The bump 162 can help reduce damage to the screen material 60 as it passes over the edge 160. Because the resilient portion 90 of the low friction material strip 88 may not extend beyond the end 160 of the of the screen edge retention feature 86, the resilient portion 90 may not be opposite the bump 162 to prevent the resilient portion 90 from pushing against the control bar 64, which may otherwise interfere with the movement of the control bar 64. Such interference could increase the force required to open the lower sash 16, or cause the control bar 64 to inadvertently disconnect from the lower sash 16. Although the bump 162 is shown and described with respect to the lower sash 16 it is understood that the same description can be applied to the upper sash 14 as an additional or alternative feature.
(79) In embodiments including the chamfered portion 154 or the transition portion 156, the bump 162 may disposed between the end 160 of the screen edge retention feature 86 and the transition portion 156.
(80) FIG. 16 is a perspective view of a portion of the upper sash 14 including the check rail seal 44 of the fenestration assembly 10 of FIG. 1, according to some embodiments of the disclosure. As shown in FIG. 16, the upper sash 14 may further include two sash terminals 164 (one visible in FIG. 16), two check rail end seals 166 (one visible in FIG. 16), and two mohair pads 168. In some embodiments, the check rail seal 44 can form two stile notches 170. In some embodiments, the check rail seal 44 can also form at least one muntin notch 172 (two shown in FIG. 16). The sash terminals 164 can engage corresponding balance shoes 180 in balance shoe channels 178 in the jambs 22, as shown in FIGS. 18 and 19.
(81) In some embodiments, the check rail seal 44 can extend the width of the upper sash 14 (e.g., along an entire length of the lower rail 26), and project from the lower rail 26 toward the lower sash 16 as shown in FIG. 2. The check rail seal 44 is flexible and able to seal against external surfaces of the lower sash 16, including the upper rail 32, the lower rail 34, the stiles 36, and the window pane 38 to reduce the number of insects and other pests that may try to pass between the upper sash 14 and the lower sash 16 (FIG. 2). Alternatively, in some embodiments, the check rail seal 44 can extend the width of the lower sash 16 (e.g., along an entire length of the upper rail 32), and project from the upper rail 32 toward the upper sash 14 to seal against external surfaces of the upper sash 14, including the upper rail 24, the lower rail 26, the stiles 28, and the window pane 30 to reduce the number of insects and other pests that may try to pass between the upper sash 14 and the lower sash 16. In some embodiments, two check rail seals 44 may be included, one projecting from the lower rail 26 toward the lower sash 16, and another projecting from the upper rail 32 toward the upper sash 14.
(82) In some embodiments, the check rail seal 44 may just physically contact the external surfaces of the lower sash 16, including the upper rail 32, the lower rail 34, the stiles 36, and the window pane 38. In some embodiments, the check rail seal 44 may physically contact the external surfaces of the lower sash 16, including the upper rail 32, the lower rail 34, the stiles 36, and the window pane 38 with an interference fit. The interference fit can be as little as 0.01 inches, 0.02 inches, 0.03 inches, 0.04 inches, or 0.05 inches, or a great as 0.06 inches, 0.08 inches, 0.10 inches or 0.12 inches, or may be within any range defined between any two of the foregoing values, such as 0.02 inches to 0.12 inches, 0.03 inches to 0.10 inches, 0.04 to 0.08 inches, 0.05 to 0.06 inches, or 0.04 inches to 0.06 inches, for example. In some other embodiments, the check rail 44 may not physically contact the external surfaces of the lower sash 16, including the upper rail 32, the lower rail 34, the stiles 36, and the window pane 38, but may form a gap small enough to discourage bugs from passing through. The gap may be as little as 0.01 inches, 0.02 inches, 0.03 inches, 0.04 inches, or 0.05 inches, or a great as 0.06 inches, 0.08 inches, 0.10 inches or 0.12 inches, or may be within any range defined between any two of the foregoing values, such as 0.02 inches to 0.12 inches, 0.03 inches to 0.10 inches, 0.04 to 0.08 inches, 0.05 to 0.06 inches, or 0.04 inches to 0.06 inches, for example, although a variety of dimensions are contemplated.
(83) The two stile notches 170 can be disposed at opposite ends of the check rail seal 44 to accommodate the stiles 28. Without the stile notches 170, portions of the check rail seal 44 displaced by the stiles 28 might be pushed outward and not be aesthetically pleasing. In embodiments including one or more muntins (not shown), a corresponding number of muntin notches 172 may be disposed between the two stile notches 170 and spaced apart from the two stile notches 170 to align with the muntins. As with the stile notches 170, without the muntin notches 172, portions of the check rail seal 44 displaced by the muntins might be pushed outward and not be aesthetically pleasing.
(84) The check rail end seals 166 can be a leaf seals configured to seal against portions of the jamb 22, as described below in reference to FIGS. 18 and 19. Each of the two check rail end seals 166 can project from opposite ends of the lower rail 26, or the upper rail 32, toward the jambs 22 to form an interference fit with the jambs 22 to discourage bugs from passing through the fenestration assembly 10 between the jamb 22 and the upper sash 14. The mohair pads 168 are disposed at the ends of the lower rail 26 to seal between the jamb 22, the check rail seal 44 and the check rail end seal 166.
(85) FIG. 17 is a side perspective view of the check rail seal 44, according to some embodiments of the disclosure. In some embodiments, the check rail seal 44 can include a seal receptor 174 and a seal strip 176 projecting from the seal receptor 174. In some embodiments, the seal receptor 174 may connect to the lower rail 26 to connect the seal strip 176 to the lower rail 26. In some embodiments (not shown), the seal receptor 174 may connect to the upper rail 32 to connect the seal strip 176 to the upper rail 32.
(86) In some embodiments, the seal strip 176 can include a plurality of monofilament fibers and form a bristle strip. The bristle strip can be thick enough to effectively block bugs, but not so thick as to be aesthetically unpleasing. The thickness of the bristle strip can be measured in the number of ends of the plurality of monofilament fibers per linear inch of the check rail seal 44. The thickness of the bristle strip can be as little as 200 ends per inch (EPI), 250 EPI, 300 EPI, 350 EPI, 400 EPI, or 500 EPI, or as great as 600 EPI, 800 EPI, 1,000 EPI, 1,200 EPI, 1,600 EPI, or 2,000 EPI, or may be within any range defined between any two of the foregoing values, such as 200 EPI to 2,000 EPI, 250 EPI to 1,600 EPI, 300 EPI to 1,200 EPI, 350 EPI to 1,000 EPI, 400 EPI to 800 EPI, 500 EPI to 600 EPI, or 300 EPI to 400 EPI, for example.
(87) In some other embodiments, the seal strip 176 can include pile, sheet, or fabric material that forms a sheet-type seal. In some embodiments, the seal strip 176 can include a polyvinylchloride-coated fiberglass screen material that forms a sheet-type seal. In yet other embodiments, the seal strip 176 can include a flexible polymer, such as nylon, polypropylene, polyethylene, or rubber, for example that forms a flexible leaf seal. In some embodiments, the seal strip 176 can include wool.
(88) In some embodiments, the seal receptor 174 and the seal strip 176 may be two separable parts. In some other embodiments, the seal receptor 174 and the seal strip 176 may bonded together to form the check rail seal 44 as a single part. In yet other embodiments, the seal receptor 174 and the seal strip 176 may be fully integrated such that the check rail seal 44 is a monolithic structure.
(89) FIGS. 18 and 19 are views of another portion of one of the jambs 22 of the fenestration assembly 10 of FIG. 1, including a balance shoe extension, according to some embodiments of the disclosure. FIG. 18 is a side view of the jamb 22 from inside the frame 12. As shown in FIG. 18, the jamb 22 may further includes a balance shoe channel 178, a balance shoe 180, and jamb covers 182. The balance shoe 180 may include a balance shoe extension 184. The balance shoe channel 178 can extend along the length of the jamb 22. The balance shoe 180 is disposed within the balance shoe channel 178 and may move along the balance shoe channel 178. The sash terminal 164 (FIG. 16) can engage the balance shoe 180 such that the balance shoe 180 and the sash terminal 164 may move together as the upper sash 14 is raised and lowered with the frame 12. The balance shoe 180 may be connected to another force, such as a spring or a weight, to counterbalance the weight of the upper sash 14, providing for smooth, easy movement of the upper sash 14 within the frame 12. The balance shoe extension 184 can be connected to the balance shoe 180. The jamb covers 182 can extend along the length of the jamb 22. The jamb covers 182 may provide a pleasing aesthetic appearance to the jamb 22.
(90) FIG. 19 is a cross-sectional view of the portion of the jamb 22 shown in FIG. 18. As shown in FIG. 19, together, the balance shoe 180 and the balance shoe extension 184 fill the balance shoe channel 178 in cross-section, providing a barrier to discourage bugs from passing through fenestration assembly 10 by way of the balance shoe channel 178. In addition, the balance shoe extension 184 provides the balance shoe 180 with a surface that is about flush with the jamb covers 182. The check rail end seal 166 can form an interference fit with the jamb 22 along the surface formed by the jamb covers 182 and the balance shoe extension 184 to discourage bugs from passing through the fenestration assembly 10 between the jamb 22 and the upper sash 14.
(91) FIG. 20 is a partial perspective view of a portion of the fenestration assembly 10, according to some embodiments of the disclosure. As shown in FIG. 20, the lower rail 34 can form a pocket 186 to accommodate the magnet 66. In the embodiment of FIG. 20, the magnet 66 is free to move vertically within the pocket 186, or to “float” within the pocket 186, while permitting the magnet 66 to project beyond a surface 188 of the lower sash 16. The vertical freedom of movement of the magnet 66 within the pocket 186 provides sufficient travel to insure that the sill seal 67 is fully seated against the sill 20 when the lower sash 16 is in the closed configuration. That is, the magnet 66 does not limit the travel of the lower sash 16.
(92) FIGS. 21A and 21B are schematic cross-sectional views of the lower rail 34 including the magnet 66, according to some embodiments of this disclosure. FIGS. 21A and 21B show that the magnet 66 can include a first portion 190 and a second portion 192. The first portion 190 is wider in the lengthwise direction of the lower rail 34 than the second portion 192. As also shown in FIGS. 21A and 21B, the lower rail 34 can further include a magnet stop 194. The magnet stop 194 can include two separate magnet stops 194, as shown, or a single magnet stop 194 that extends around a perimeter of the pocket 186. The magnet stop 194 is disposed at the surface 188 of the lower sash 16 and projects into the pocket 186. FIG. 21A shows the magnet 66 in a first position in which the magnet 66 does not project beyond the surface 188 of the lower sash 16. FIG. 21B shows the magnet 66 in a second position in which a portion of the magnet 66 projects beyond the surface 188 of the lower sash 16. The magnet stop 194 projects into the pocket 186 such that movement of the second portion 192 of the magnet 66 is not impeded, while movement of the first portion 190 is restricted by the magnet stop 194. Thus, as shown in FIG. 21B, when the control bar 64 approaches the surface 188 of the lower sash 16, such as when the lower sash 16 is in the closed configuration, the control bar 64 automatically engages the magnet 66, thus attaching the control bar 64 to the lower sash 16. By floating within the pocket 186, the magnet 66 can be continuously moveable between the first position and the second position.
(93) Although the embodiments of FIGS. 20, 21A, and 21B are shown and described with respect to the lower screen assembly 42 and a single magnet 66, it is understood that the same description can be applied to a plurality of magnets 66, and to the upper screen assembly 40 and one or more magnets 54 (FIG. 2).
(94) FIGS. 22A and 22B are cross-sectional views of the jamb 22 of the fenestration assembly 10 of FIG. 1, where the lower sash 16 can slideably engage the jamb 22, according to some embodiments of the disclosure. In FIG. 22A, a portion of the screen material 60 has been unwound from the roller assembly 58 of the lower screen assembly 42 by moving the lower sash 16 away from the sill 20, as shown in FIGS. 1 and 2. As shown in FIG. 22A, each of the jambs 22 include the first slot 71 formed by the jamb 22. Although only one of the two jambs 22 is shown in FIG. 22A for ease of illustration, it is understood that each of the jambs 22 includes the first slot 71, thus, fenestration assembly 10 includes two first slots 71. The control bar 64 is wider than the lower sash 16 so that it can project into the first slots 71 of each of the two jambs 22 as screen material 60 is unwound from the roller assembly 58.
(95) In FIG. 22B, the lower sash 16 has been moved away from the sill 20 to a point where it is desirable that the control bar 64 be disengaged from the magnet 66. As shown in the embodiment of FIG. 22B, each of the first slots 71 includes a stop 196. The stop 196 presents a barrier to the continued travel of the control bar 64 along the first slot 71, and thus separates the control bar 64 from the magnet 66 as the lower sash 16 is moved beyond the point where it is desirable that the control bar 64 be disengaged from the magnet 66. In this way, the stops 196 are configured to prevent movement of the control bar 64 beyond the stops 196, and automatically disengage the control bar 64 from the magnet 66 if the lower sash 16 moves beyond the stops 196. Once the control bar 64 is disengaged from the magnet 66, the tension applied to the end 62 of the screen material 60 is eliminated, permitting the rotational bias of the roller assembly 58 to wind the screen material 60 around the roller assembly 58.
(96) FIGS. 23A and 23B are cross-sectional views of the jamb 22 of the fenestration assembly 10 of FIG. 1, where the where the upper sash 14 can slideably engage the jambs 22, according to some embodiments of the disclosure. In FIG. 23A, a portion of the screen material 48 has been unwound from the roller assembly 46 of the upper screen assembly 40 by moving the upper sash 14 away from the head 18, as shown in FIGS. 1 and 2. As shown in FIG. 23A, each of the jambs 22 can include the second slot 74 formed by the jamb 22. Although only one of the two jambs 22 is shown in FIG. 23A for ease of illustration, it is understood that each of the jambs 22 includes the second slot 74, thus, fenestration assembly 10 includes two second slots 74. The control bar 52 is wider than the upper sash 14 so that it can project into the second slots 74 of each of the two jambs 22 as screen material 48 is unwound from the roller assembly 46.
(97) In FIG. 23B, the upper sash 14 has been moved away from the head 18 to a point where it is desirable that the control bar 52 be disengaged from the magnet 54. As shown in the embodiment of FIG. 23B, each of the second slots 74 includes a stop 198. The stop 198 presents a barrier to the continued travel of the control bar 52 along the second slot 74, and thus separates the control bar 52 from the magnet 54 as the upper sash 14 is moved beyond the point where it is desirable that the control bar 52 be disengaged from the magnet 54. In this way, the stops 198 are configured to prevent movement of the control bar 52 beyond the stops 198, and automatically disengage the control bar 52 from the magnet 54 if the upper sash 14 moves beyond the stops 198. Once the control bar 52 is disengaged from the magnet 54, the tension applied to the end 50 of the screen material 48 is eliminated, permitting the rotational bias of the roller assembly 46 to wind the screen material 48 around the roller assembly 46.
(98) FIGS. 24A and 24B are perspective views of a screen release mechanism, according to some embodiments of this disclosure. FIG. 24A shows a portion of the lower sash 16 including the magnet 66 at least partially within the pocket 186. In the embodiment of FIG. 24A, the lower sash 16 further includes an ejector 200 and ejector ribbon 201. The ejector 200 faces the control bar 64 (omitted here for clarity, see FIGS. 20 and 21B). FIG. 24A shows the ejector 200 in a first position in which the ejector 200 is at or below the surface 188 of the lower sash 16. FIG. 24B shows the ejector 200 in a second position in which a portion of the ejector 200 projects beyond the surface 188 of the lower sash 16 to disengage the control bar 64 from the magnet 66. Once the control bar 64 is disengaged from the magnet 66, the tension applied to the end 62 of the screen material 60 is eliminated, permitting the rotational bias of the roller assembly 58 to wind the screen material 60 around the roller assembly 58. The ejector ribbon 201 may be made of fabric and be mechanically connected to the ejector 200. The ejector 200 can be activated by pulling on the ejector ribbon 201. In other embodiments, the ejector 200 can be activated by other means mechanically connected to the ejector 200, such as a switch, push button, or lever, for example.
(99) FIGS. 25A and 25B are cross-sectional views of a portion of another fenestration assembly, according to some embodiments of this disclosure. FIGS. 25A and 25B show a fenestration assembly 202 which can be substantially similar to the fenestration assembly 10 discussed above, except that in the fenestration assembly 202, the lower sash 16 is configured to tilt out of a plane P of the frame 12 (FIG. 1) about a pivot point 204. FIG. 25A shows the fenestration assembly 202 with the lower sash 16 in the plane P and FIG. 25B shows the fenestration assembly 202 with the lower sash 16 tilted out of the plane P. The ability to tilt the lower sash 16 out of a plane P permits access to an external surface of the window pane 38 for cleaning. In the embodiment of FIGS. 25A and 25B, the lower sash 16 further includes a rail slope 206. The rail slope 206 is an angled portion of the lower rail 34 adjacent to the magnet 66. Considering FIGS. 25A and 25B together, as the lower sash 16 is tilted out of the plane P and about the pivot point 204 in a direction D1, the rail slope 206 wedges between the magnet 66 and the control bar 64. The control bar 64 moves along the rail slope 206 in a direction D2, away from the magnet 66. Once sufficiently separated from the magnet 66, the control bar 64 disengages from the magnet 66. The rotational bias of the roller assembly 58 moves the control bar 64 in the direction D3 as it winds the screen material 60 around the roller assembly 58.
(100) Although the embodiments of FIGS. 24A, 24B, 25A, and 25B are shown and described with respect to the lower screen assembly 42 it is understood that the same description can be applied to the upper screen assembly 40. In addition, is understood that the embodiment of FIGS. 25A and 25B can include any of the features shown in FIGS. 20, 21A, 21B, 22A, 22B, 23A, 23B, 24A, and 24B.
(101) FIGS. 26A and 26B are cross-sectional views of another magnet and portion of a screen assembly, according to some embodiments of this disclosure. FIG. 26A shows a portion of the lower screen assembly 42 as describe above in reference to FIGS. 1 and 2, including the control bar 64 disposed at the end 62 of the screen material 60 (the remainder of the fenestration assembly 10 is omitted for clarity). In the embodiment of FIG. 26A, the magnet 66 described in embodiments above can be replaced by cylindrical magnet 208. The cylindrical magnet 208 is rotatable about a longitudinal axis A to disengage the control bar 64 from the cylindrical magnet 208. The cylindrical magnet 208 is polarized across its diameter, resulting in a north pole segment 210 diametrically opposed to a south pole segment 212. In FIG. 26A, the south pole segment 212 is directed toward the control bar 64, resulting in a strong magnetic force or attraction between the control bar 64 and the cylindrical magnet 208. This first level of magnetic force is sufficient to engage the control bar 64. An equally strong magnetic force would be formed if the cylindrical magnet 208 were rotated 180 degrees about its longitudinal axis A such that the north pole segment 210 were directed toward the control bar 64. However, as the cylindrical magnet 208 is rotated about its longitudinal axis A between these orientations, the magnetic force or attraction between the control bar 64 and the cylindrical magnet 208 diminishes.
(102) In FIG. 26B, the cylindrical magnet 208 has been rotated about its longitudinal axis A such that the north pole segment 210 and the south pole segment 212 are directed at right angles away from the control bar 64, resulting in a negligible magnetic attraction between the control bar 64 and the cylindrical magnet 208. This second level of magnetic force is insufficient to engage the control bar 64. Thus, in the embodiment of FIGS. 26A and 26B, rotating the cylindrical magnet 208 about its longitudinal axis A varies the magnetic force in the direction of the control bar 64 between a first level of magnetic force sufficient to engage the control bar 64 and a second level of magnetic force insufficient to engage the control bar 64. Once the control bar 64 is rotated to the second level of magnetic force, the rotational bias of the roller assembly 58 disengages the control bar 64 from the cylindrical magnet 208 and moves the control bar 64 in the direction D3 as it winds the screen material 60 around the roller assembly 58 (FIG. 2).
(103) Although the embodiment of FIGS. 26A and 26B is shown and described with respect to the lower screen assembly 42, it is understood that the same description can be applied to the upper screen assembly 40.
(104) Various modifications and additions can be made to the examples discussed without departing from the scope of the present disclosure. For example, while the examples described above refer to particular features, the scope of this disclosure also includes examples having different combinations of features and examples that do not include all of the above described features.
