Mullion Pin Anchor Cleats for Fenestration Frame Alignment

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Solution Overview

Problem

The installation of mullion assemblies in fenestration systems is labor-intensive and time-consuming due to the need for precise alignment and the risk of deformation or breakage of connection brackets, and the cumbersome nature of composite fenestration assemblies makes fine manipulation and alignment within a rough opening challenging.

Innovation Solution

A mullion system that includes a mullion pin with anchor cleats that can be inserted into complementary cleat recesses of fenestration frames, allowing for easy alignment and locking of fenestration assemblies without the need for shimming or fastening, using a tapered clamping mechanism to secure the assemblies together.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If connection brackets are struck with a rubber mallet or hammer during installation, then the brackets can be driven into complementary kerfs, but the brackets are subject to deformation and breakage

Engineering Contradiction:

Improveinstallation of connection bracketsVSAvoidintegrity of connection brackets

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The mullion pin is designed with pre-formed anchor cleats that are already positioned and oriented correctly before installation. This preliminary configuration eliminates the need to strike brackets during installation, preventing deformation and breakage while ensuring proper alignment with the kerfs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mullion pin acts as an intermediary component that transfers the alignment and coupling function between the first and second fenestration frames. Instead of directly striking connection brackets, the mullion pin with its anchor cleats provides a mediating mechanism that achieves coupling without harmful impact forces.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If component fenestration assemblies are arranged and aligned on assembly tables or sawhorses, then access to interconnecting features is facilitated, but the assemblies require precise alignment before mullion installation

Engineering Contradiction:

Improveaccess to interconnecting featuresVSAvoidalignment of fenestration assemblies

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The coupling system is segmented into modular components: the mullion pin, anchor cleats, and kerfs. This segmentation allows each component to be independently manufactured and then assembled, reducing the need for precise pre-alignment of entire fenestration assemblies. The anchor cleats can be independently positioned to match the kerfs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mullion pin with anchor cleats is designed to self-align with the kerfs during installation. The geometry of the anchor cleats and kerfs creates a self-guiding mechanism that facilitates automatic alignment, reducing the need for manual adjustment and precise pre-positioning of the fenestration assemblies.

Inventive Principle:

Principle #25Self-service

3Weight of stationary object

If the composite fenestration assembly is raised into place with multiple technicians or a lift, then the heavy assembly can be installed, but fine manipulation and adjustment of the assembly within the rough opening becomes difficult

Engineering Contradiction:

Improveweight of composite fenestration assemblyVSAvoidfine manipulation within rough opening

Core Design Contradiction:

Weight of stationary objectVSEase of operation

Solution Approach 1:

The fenestration system is divided into separate component assemblies that are coupled through the mullion pin mechanism. This segmentation allows the components to be installed and manipulated independently with less weight, and the mullion pin coupling can be adjusted after initial positioning, enabling fine manipulation even after the assembly is raised into place.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mullion pin coupling mechanism provides dynamic adjustability after installation. The pin can be removed and reinserted, or the anchor cleats can be adjusted within the kerfs, allowing for fine manipulation and alignment adjustments even after the heavy composite assembly has been raised into the rough opening.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Facilitates efficient and precise installation of mullion assemblies during or before placing fenestration assemblies in a rough opening, reducing labor and time while ensuring robust coupling and alignment of fenestration frames, minimizing deformation and breakage risks.

Implementation Method 1

using a tapered clamping mechanism to secure the assemblies together

Methodology Applied

Scientific EffectTapered clamping mechanism: Wedge

Data Source

PatentUS20230383588A1Mullion systems and methods for the same

Publication Date: 2023.11.30 MARVIN LUMBER & CEDAR COMPANY D B A MARVIN WINDOWS & DOORS

AI summary

A mullion assembly includes at least one mullion pin configured to clamp proximate fenestration frame members together. The at least one mullion pin includes a pin body configured for movable coupling between the proximate fenestration frame members. First and second anchor cleats extend from the pin body. The at least one mullion pin is movable from an introduced configuration to a locked configuration. In the locked configuration the first and second anchor cleats are configured to clamp the fenestration frame members together.