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US 10,626,664 B1Granted
Compound fenestration assembly mull joints and methods
AssigneeAndersen Corporation
InventorsTimothy J. Kelley, Duane Fier, Jeremiah Boe, Jon Dekko
Life of this patent
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Abstract
Compound fenestration assembly mull joints, compound fenestration assemblies using those mull joints, and methods of making and using the same are described herein. The mull joints in compound fenestration assemblies as described herein use universal joining strips to form both sides of a mull joint, as well as other universal components such as, e.g., corner gussets, locator plates, end plugs, seal members, etc. that may be used as needed to form mull joints as required in a compound fenestration assembly.
Claims34
A compound fenestration assembly comprising:
- a first frame member of a first fenestration unit attached to a second frame member of a second fenestration unit along a mull joint having a first end and a second end,
- wherein the mull joint defines a mull joint axis extending along a length of the mull joint between the first and second ends of the mull joint,
- wherein the first and second frame members comprise exterior sides facing in the same direction and interior sides facing in an opposite direction from the exterior sides, wherein an interior/exterior axis extends between the interior and exterior sides in a direction transverse to the mull joint axis,
- wherein the first frame member faces the second frame member across the mull joint, wherein a separation axis extends through the mull joint between the first and second frame members, the separation axis extending in a direction transverse to both the mull joint axis and the interior/exterior axis;
- a first joining strip attached to the first frame member of the first fenestration unit, the first joining strip comprising a first end proximate the first end of the mull joint, wherein the first joining strip comprises a channel aligned with the mull joint axis, the channel opening towards the exterior side of the first fenestration unit;
- a second joining strip attached to the second frame member of the second fenestration unit, the second joining strip comprising a first end proximate the first end of the mull joint, wherein the second joining strip comprises a channel aligned with the mull joint axis, the channel opening towards the interior side of the second fenestration unit such that the channel on the first joining strip mechanically interlocks with the channel on the second joining strip, wherein the mechanically interlocking channels prevent movement of the first frame member away from the second frame member along the separation axis, prevent movement of the first frame member towards the exterior side of the second frame member along the interior/exterior axis, and prevent movement of the second frame member towards the interior side of the first frame member along the interior/exterior axis;
- a corner gusset assembly at the first end of the mull joint, the corner gusset assembly comprising:
- an adjustable corner gusset attached to the first fenestration unit, wherein the adjustable corner gusset comprises:
- a corner gusset leg positioned between the first joining strip and the first frame member of the first fenestration unit at the first end of the mull joint, wherein the corner gusset leg is fixed in position along the interior/exterior axis relative to the first frame member of the first fenestration unit to restrict movement of the corner gusset along the interior/exterior axis, and wherein the corner gusset leg comprises an exposed end protruding away from the first end of the first joining strip;
- a base plate extending away from a corner of the first fenestration unit proximate the first end of the mull joint, wherein the base plate extends away from the first fenestration unit in a direction aligned with the separation axis, wherein the base plate is configured for attachment to an interior surface of an opening in which the first fenestration unit is located to restrict movement of the base plate along the interior/exterior axis, and
- a sliding junction between the corner gusset leg and the base plate, wherein the sliding junction comprises a tab and a slot, wherein the tab and the slot form a tab and slot assembly between the corner gusset leg and the base plate, wherein the tab and slot assembly restricts movement of the corner gusset leg along the interior/exterior axis while allowing the corner gusset leg to move along the separation axis such that the first frame member is configured to move relative to the base plate along the separation axis while being restricted from movement relative to the base plate along the interior/exterior axis.
8 more elements
A compound fenestration assembly comprising:
- a first frame member of a first fenestration unit attached to a second frame member of a second fenestration unit along a mull joint having a first end and a second end,
- wherein the mull joint defines a mull joint axis extending along a length of the mull joint between the first and second ends of the mull joint,
- wherein the first and second frame members comprise exterior sides facing in the same direction and interior sides facing in an opposite direction from the exterior sides, wherein an interior/exterior axis extends between the interior and exterior sides in a direction transverse to the mull joint axis,
- wherein the first frame member faces the second frame member across the mull joint, wherein a separation axis extends through the mull joint between the first and second frame members, the separation axis extending in a direction transverse to both the mull joint axis and the interior/exterior axis;
- a first joining strip attached to the first frame member of the first fenestration unit, the first joining strip comprising a first end proximate the first end of the mull joint, wherein the first joining strip comprises a channel aligned with the mull joint axis, the channel opening towards the exterior side of the first fenestration unit;
- a second joining strip attached to the second frame member of the second fenestration unit, the second joining strip comprising a first end proximate the first end of the mull joint, wherein the second joining strip comprises a channel aligned with the mull joint axis, the channel opening towards the interior side of the second fenestration unit such that the channel on the first joining strip mechanically interlocks with the channel on the second joining strip, wherein the mechanically interlocking channels prevent movement of the first frame member away from the second frame member along the separation axis, prevent movement of the first frame member towards the exterior side of the second frame member along the interior/exterior axis, and prevent movement of the second frame member towards the interior side of the first frame member along the interior/exterior axis;
- a corner gusset assembly at the first end of the mull joint, the corner gusset assembly comprising:
- a corner gusset leg positioned between the first joining strip and the first frame member of the first fenestration unit at the first end of the mull joint, wherein the corner gusset leg is fixed in position along the interior/exterior axis relative to the first frame member of the first fenestration unit to restrict movement of the corner gusset along the interior/exterior axis, and
- a base plate attached to the corner gusset leg and extending away from a corner of the first fenestration unit proximate the first end of the mull joint, wherein the base plate extends away from the first fenestration unit in a direction aligned with the separation axis, wherein base plate is configured for attachment to an interior surface of an opening in which the first fenestration unit is located, and wherein the retainer plug recess is located between the base plate and the first ends of the first and second joining strips proximate the first end of the mull joint;
- a retainer plug recess at the first end of the mull joint, the retainer plug recess located between the first frame member of the first fenestration unit and the second frame member of the second fenestration unit;
- a retainer plug bracket attached to the second fenestration unit, wherein the retainer plug bracket comprises a bracket leg positioned between the second joining strip and the second frame member of the second fenestration unit at the first end of the mull joint, wherein the bracket leg is fixed in position along the interior/exterior axis relative to the second frame member of the second fenestration unit to restrict movement of the retainer plug bracket along the interior/exterior axis;
- and
- a retainer plug seated in the retainer plug recess, wherein the retainer plug mechanically interlocks with both the corner gusset leg and the bracket leg when the retainer plug is in a seated position and a locked orientation in the retainer plug recess, wherein the mechanical interlock between the retainer plug and both the corner gusset leg and the bracket leg restricts movement of the first and second joining strips relative to each other along the interior/exterior axis that would result in disengagement of the channels on the first and second joining strips from each other.
10 more elements
A method of forming a mull joint between a first frame member of a first fenestration unit and a second frame member of a second fenestration unit, the method comprising:
- attaching a base plate of an adjustable corner gusset assembly to a framing member of an opening configured to receive the first and second fenestration units;
- attaching a corner gusset leg attached to the first frame member of the first fenestration unit to the base plate after attaching the base plate to the framing member, wherein attaching the corner gusset leg to the base plate comprises forming a sliding junction between the corner gusset leg and the base plate, wherein the sliding junction comprises a tab and slot assembly;
- aligning the second frame member of the second fenestration unit with the first frame member of the first fenestration unit after attaching the corner gusset leg to the base plate such that an exterior side of the second fenestration unit is aligned with an exterior side of the first fenestration unit and an interior side of the first fenestration is aligned with an interior side of the second fenestration unit, wherein a mull joint axis extends between and is aligned with the first frame member and the second frame member, and wherein the aligning mechanically interlocks a channel on a first joining strip attached to the first frame member with a channel on a second joining strip attached to the second frame member, wherein the channel on the first joining strip is aligned with the mull joint axis and opens towards the exterior side of the first fenestration unit, and wherein the second channel is aligned with a mull joint axis and opens towards the interior side of the second fenestration unit, wherein the mechanically interlocked channels prevent movement of the first frame member away from the second frame member along a separation axis extending through the first and second frame members and the first and second joining strips in a direction transverse to the mull joint axis;
- locking the second fenestration unit in position relative to the first fenestration unit after mechanically interlocking the channels on the first and second joining strips by one or more of:
- inserting a retainer plug into a retainer plug recess provided at one end of the first and second joining strips, wherein the retainer plug recess is formed between the first frame member of the first fenestration unit and the second frame member of the second fenestration unit, wherein the retainer plug forms a mechanical interlock between the first and second fenestration units;
- inserting a cavity leg of a first end plug in an opening of an intermediate end plug cavity, wherein the intermediate end plug cavity is formed between the first joining strip and the second joining strip when the channels on the first and second joining strips are mechanically interlocked with each other, wherein the cavity leg prevents disengagement of the mechanically interlocking channels on the first and second joining strips at the first ends of first and second joining strips;
- inserting a trim strip into a trim slot formed between the first and second joining strips, the trim slot being located between the first frame member of the first fenestration unit and the second frame member of the second fenestration unit.
4 more elements
A compound fenestration assembly comprising:
- a first frame member of a first fenestration unit attached to a second frame member of a second fenestration unit along a mull joint having a first end and a second end,
- wherein the mull joint defines a mull joint axis extending along a length of the mull joint between the first and second ends of the mull joint,
- wherein the first and second frame members comprise exterior sides facing in the same direction and interior sides facing in an opposite direction from the exterior sides, wherein an interior/exterior axis extends between the interior and exterior sides in a direction transverse to the mull joint axis,
- wherein the first frame member faces the second frame member across the mull joint, wherein a separation axis extends through the mull joint between the first and second frame members, the separation axis extending in a direction transverse to both the mull joint axis and the interior/exterior axis;
- a first joining strip attached to the first frame member of the first fenestration unit, the first joining strip comprising a first end proximate the first end of the mull joint, wherein the first joining strip comprises a channel aligned with the mull joint axis, the channel opening towards the exterior side of the first fenestration unit;
- a second joining strip attached to the second frame member of the second fenestration unit, the second joining strip comprising a first end proximate the first end of the mull joint, wherein the second joining strip comprises a channel aligned with the mull joint axis, the channel opening towards the interior side of the second fenestration unit such that the channel on the first joining strip mechanically interlocks with the channel on the second joining strip, wherein the mechanically interlocking channels prevent movement of the first frame member away from the second frame member along the separation axis, prevent movement of the first frame member towards the exterior side of the second frame member along the interior/exterior axis, and prevent movement of the second frame member towards the interior side of the first frame member along the interior/exterior axis;
- a corner gusset assembly at the first end of the mull joint, the corner gusset assembly comprising:
- an adjustable corner gusset attached to the first fenestration unit, wherein the adjustable corner gusset comprises:
- a corner gusset leg positioned between the first joining strip and the first frame member of the first fenestration unit at the first end of the mull joint, wherein the corner gusset leg is fixed in position along the interior/exterior axis relative to the first frame member of the first fenestration unit to restrict movement of the corner gusset along the interior/exterior axis, and wherein the corner gusset leg comprises an exposed end protruding away from the first end of the first joining strip,
- a base plate extending away from a corner of the first fenestration unit proximate the first end of the mull joint, wherein the base plate extends away from the first fenestration unit in a direction aligned with the separation axis, wherein the base plate is configured for attachment to an interior surface of an opening in which the first fenestration unit is located to restrict movement of the base plate along the interior/exterior axis, and
- a sliding junction between the corner gusset leg and the base plate, wherein the sliding junction is configured to restrict movement of the corner gusset leg and the base plate relative to each other along the interior/exterior axis and also configured to allow the corner gusset leg to move relative to the base plate along the separation axis such that the first frame member is configured to move relative to the base plate in two opposing directions along the separation axis while being restricted from movement relative to the base plate along the interior/exterior axis;
- wherein the tab extends from the corner gusset leg and the slot is formed in the base plate;
- and wherein the tab comprises a foot extending along the seperation axis such that at least a portion of the foot is located in the slot.
10 more elements
Dependencies are inferred from the claim text.