Mullion End Cap Seal with Integrated Fastener Bosses
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Solution Overview
Problem
Conventional window frame assemblies face challenges in efficiently coupling mullion and frame members while maintaining effective water performance and durability, often requiring additional sealants that complicate maintenance and can trap water, leading to long-term damage.
Innovation Solution
The use of a mullion end cap with a molded seal and integrated fastener bosses that provide a sealed joint without external sealants, allowing for drainage of water through slots and slits, and a connection system that distributes load through reinforcement members without relying on mullion material strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealants are applied to seal fastener openings, then water intrusion is minimized, but maintenance becomes difficult and water can be trapped leading to long-term damage
Solution Approach 1:
The joint assembly is segmented into distinct functional components: a seal member that provides water sealing, a fastener that provides mechanical connection, and a drainage system with exit points that allows water removal. This segmentation allows each component to perform its function independently, with the seal member preventing water intrusion and the drainage system providing outlets for any penetrating water, while fasteners remain accessible for maintenance.
Solution Approach 2:
The seal member acts as an intermediary element between the fastener and the joint surfaces. It provides the sealing function without requiring direct contact with water, while the drainage system serves as an intermediary pathway for water removal. This intermediary approach allows the fastener to remain accessible for maintenance while still achieving effective water sealing.
2Strength
If fasteners extend through both members to join mullion and frame, then structural connection is achieved, but leakage occurs at the fastener penetration points
Solution Approach 1:
The seal member is positioned locally at the fastener penetration points, providing enhanced sealing exactly where water leakage occurs. This localized sealing approach allows the fastener to maintain its structural connection function while the seal member prevents water intrusion at the critical penetration locations.
Solution Approach 2:
The seal member serves as an intermediary barrier between the fastener and the water environment. It allows the fastener to provide structural connection while preventing water from penetrating through the fastener openings, thus eliminating the harmful leakage effect without compromising the strength of the joint connection.
3Adaptability or versatility
If multiple components are used in complex window assemblies, then design flexibility is improved, but construction time and complexity increase
Solution Approach 1:
The seal member, fastener, and drainage system are merged into an integrated joint assembly that functions as a single unified component. This merging reduces the number of separate parts that need to be handled, installed, and maintained, while still providing the design flexibility needed for complex window assemblies through modular configuration of the integrated assembly.
Data Source
AI summary
The disclosure relates generally to a window assembly designed to facilitate the construction process by providing a simple and efficient method for joining mullion members and frame members along a window joint. The assembly includes a mullion end cap with a seal extending around the periphery of the end cap to help minimize moisture entry into the window assembly via the window joints. In addition, the seal includes fastener bosses designed to seal against fasteners extending therethrough to help seal the joint without need for separately applying a silicone or other sealant in a post-assembly process.