Mull Sealing Cap and Connector for Flexible Fenestration Mulling
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Solution Overview
Problem
Existing methods for mulling windows and doors together, either at the factory or on-site, face challenges such as increased labor, complexity, and risk of injury or damage due to oversized units being lifted into place.
Innovation Solution
A system and method for mulling fenestration assemblies using a mull connector and end cap that secures fenestration frames together without separate fasteners, with a channel for sealant application to create a weather-tight seal, and beveled engagement members for alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If field mulling is used to connect fenestration assemblies on the jobsite, then flexibility in installation is improved, but labor complexity and installation time increase
Solution Approach 1:
The mull connector is divided into separate modular components including engagement members with flanges that attach to individual fenestration frames, allowing independent assembly of each frame unit before final connection. This segmentation enables flexible field mulling while reducing overall installation complexity through standardized modular components.
Solution Approach 2:
The mull connector acts as an intermediary component between separate fenestration assemblies, providing a standardized interface that simplifies the connection process. The connector includes engagement members, flanges, and sealing surfaces that mediate the joining process, reducing labor complexity while maintaining installation flexibility.
2Productivity
If oversized mulled units are lifted into building openings, then installation efficiency is improved, but risk of injury and damage increases
Solution Approach 1:
The system allows fenestration assemblies to be segmented into manageable units that can be individually handled and installed, then connected using the mull connector. This reduces the size and weight of units that must be lifted into place, minimizing injury and damage risks while maintaining overall installation efficiency through the modular connection system.
Solution Approach 2:
Fenestration assemblies can be pre-assembled with mull connectors attached in the factory or staging area, allowing individual units to be prepared in advance and then easily installed. This preliminary action reduces on-site lifting operations and associated risks while maintaining installation efficiency.
3Strength
If separate fasteners are used to secure fenestration frames together, then connection strength is improved, but device complexity and assembly time increase
Solution Approach 1:
The mull connector merges multiple functions into a single integrated component: engagement members for mechanical attachment, flanges for frame connection, and sealing surfaces for weatherproofing. This consolidation provides strong connections while reducing assembly complexity by eliminating the need for multiple separate fasteners and sealing components.
Solution Approach 2:
The mull connector is designed as a universal component that performs multiple functions simultaneously: structural connection, alignment, and sealing. The engagement members with flanges provide both mechanical strength and simplified assembly, while integrated sealing surfaces eliminate the need for separate gaskets or seals, reducing overall device complexity.
4Reliability
If traditional sealing methods are used between mulled assemblies, then weatherproofing is achieved, but labor time and complexity increase
Solution Approach 1:
The sealing surface is merged into the mull connector itself, combining the sealing function with the structural connection component. This integration eliminates the need for separate sealing materials and application steps, achieving reliable weatherproofing while significantly reducing sealing time and labor complexity.
Solution Approach 2:
The mull connector includes self-contained sealing surfaces that automatically provide weatherproofing when the connector is properly installed. The sealing function is built into the connector structure, allowing it to self-seal the joint between fenestration assemblies without requiring additional sealing materials or complex application procedures.
Data Source
AI summary
A system for mulling a first fenestration frame and a second fenestration frame together, including a first fenestration frame having a first jamb and a second jamb; a second fenestration frame having a first jamb and a second jamb; a mull connector securing the first fenestration frame and the second fenestration frame together, and an end cap including a body operatively secured to a first end of the mull connector and including a channel extending about a front portion of the body of the end cap.