H-Shaped Mull Connector for Fenestration Assembly
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Solution Overview
Problem
Field mulling of windows and doors is labor-intensive and risky due to the need for on-site assembly and sealing, which can lead to installer injuries and damage to the mulled units, especially when dealing with oversized units that cannot be factory-mulled due to size, weight, or shipping constraints.
Innovation Solution
A system and method for mulling fenestration assemblies using H-shaped mull connectors and sealing caps that allow for the connection and sealing of multiple fenestration units in a building opening, enabling each unit to be installed separately or together, with mull halves and connectors facilitating secure and safe assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If field mulling is performed to accommodate oversized units that cannot be factory-mulled, then adaptability to size and shipping constraints is improved, but labor intensity and installation complexity increase
Solution Approach 1:
The mulling system is divided into separate modular components including individual mull connectors that attach to pre-installed window units. Each connector is a self-contained element that can be independently installed, eliminating the need for complex on-site assembly of entire mull assemblies. The segmentation allows installers to work with manageable individual components rather than oversized pre-assembled units.
Solution Approach 2:
Window units are pre-equipped with attachment features (such as flanges or mounting surfaces) during manufacturing, and mull connectors are prepared in advance with pre-drilled holes and pre-applied sealants. This preliminary preparation eliminates the need for on-site drilling, sealing, and complex assembly operations, significantly reducing installation complexity while maintaining adaptability to various window sizes.
2Adaptability or versatility
If field mulling is performed to accommodate oversized units, then shipping constraints are overcome, but risk of installer injury and unit damage increases
Solution Approach 1:
The system separates the heavy window units from the mulling components, allowing units to be installed individually at manageable weights. The mull connectors are small, lightweight elements that are easily handled. This segmentation eliminates the need to lift and maneuver oversized pre-assembled mull assemblies, directly reducing the risk of installer injury and unit damage while still enabling the installation of oversized window configurations.
Solution Approach 2:
Mull connectors serve as intermediary elements that join pre-installed window units without requiring the handling of large composite assemblies. The connectors act as mediators that transfer structural loads between units through simple attachment points, eliminating the need for installers to manipulate oversized combined units and thereby reducing physical risk.
3Ease of operation
If factory mulling is performed, then installation simplicity is improved, but size and weight constraints limit applicability
Solution Approach 1:
Window units are manufactured with pre-integrated attachment features (flanges, mounting surfaces, or connection points) that prepare them for field mulling. This preliminary action during manufacturing creates a system as simple as factory mulling, where components are designed to fit together without complex on-site fabrication, while simultaneously enabling adaptability to oversized units that would be impossible to factory-mull due to size constraints.
4Adaptability or versatility
If on-site assembly and sealing is required for field mulling, then adaptability to various opening sizes is improved, but labor intensity and time consumption increase
Solution Approach 1:
Mull connectors are manufactured with pre-applied sealants, pre-drilled fastening holes, and pre-formed geometric configurations that match standard window unit interfaces. This preliminary preparation eliminates the need for on-site sealing operations and complex measurements, allowing installers to simply attach connectors to pre-installed units. The system maintains adaptability to various opening sizes while reducing labor intensity and installation time through this advance preparation.
Solution Approach 2:
The mull connectors are designed as self-contained units that include their own sealing, fastening, and alignment features. The connectors self-align with window unit attachment points through geometric matching, and pre-applied sealants automatically seal joints upon attachment. This self-service design eliminates the need for additional sealing operations and complex alignment procedures, significantly reducing labor intensity while maintaining versatility.
Data Source
AI summary
A system for mulling a plurality of fenestration assemblies in an opening includes a first fenestration assembly having a top surface and a first groove extending therein and a second fenestration assembly having a top surface and a second groove extending therein. A mull connector operatively connects the first fenestration assembly and second fenestration assembly together. A sealing cap is positioned on top of the mull connector and includes a first portion positioned on a first side of a line groove line defined by the first groove and the second groove, and a second portion positioned on the second opposite side of the line groove.