Sliding Mull Connector for Fenestration Frame Assembly
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Solution Overview
Problem
The existing methods for mulling windows and doors, either factory or field mulling, face challenges such as increased labor and complexity, risk of injury, and potential damage due to the need for assembling and sealing oversized units on-site, which complicates the installation process and poses safety hazards.
Innovation Solution
A system and method involving a primary mull connector with jamb engagement portions and secondary connectors, along with weather stripping and sealants, allows for the sliding connection and secure sealing of fenestration frames, enabling either individual or simultaneous installation of multiple fenestration assemblies, reducing on-site assembly complexity and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If field mulling is performed to assemble oversized units on-site, then factory size and shipping limits are exceeded, but labor and complexity increase significantly
Solution Approach 1:
The mull system is divided into separate modular components including primary mull connectors, secondary mull connectors, end covers, and weather stripping. These segments can be independently manufactured and then assembled on-site through simple connection operations, eliminating the need for complex field assembly while still allowing oversized units to be created by combining multiple fenestration assemblies.
2Adaptability or versatility
If field mulling is performed to assemble oversized units on-site, then factory size and shipping limits are exceeded, but labor requirements increase significantly
Solution Approach 1:
The primary and secondary mull connectors, end covers, and weather stripping are pre-manufactured and prepared in advance. This preliminary preparation of connection components eliminates the need for complex on-site fabrication or assembly operations, allowing installers to simply connect pre-assembled fenestration assemblies with pre-prepared connectors, thereby maintaining high installation speed while enabling oversized unit configurations.
3Ease of operation
If oversized mulled units are lifted into the opening, then installation is completed in one piece, but risk of injury and damage increases
Solution Approach 1:
The system allows fenestration assemblies to remain as separate, manageable units during installation rather than being pre-assembled into one large oversized unit. The modular mull connectors enable these separate units to be safely installed individually and then connected on-site, eliminating the need to lift and maneuver dangerous oversized assemblies while still achieving the desired multi-unit configuration.
4Ease of operation
If factory mulling is performed to assemble units before shipping, then installation is simplified, but shipping limits are exceeded
Solution Approach 1:
Instead of assembling complete oversized mulled units in the factory, the system segments the mulling function into separate connectors that are manufactured at the factory. The fenestration assemblies themselves remain separate and shipable, while the factory-manufactured connectors enable simple on-site connection, achieving installation simplicity without exceeding shipping size limits.
Solution Approach 2:
The mull connectors serve as intermediary components that bridge separate fenestration assemblies. These connectors are manufactured in the factory with precise engagement features, and they mediate the connection between separate field-assembled units, providing the simplicity of factory precision while maintaining the flexibility of field assembly for oversized configurations.
Data Source
AI summary
A system for mulling a plurality a first fenestration frame and a second fenestration frame including a primary mull connector that is sliding received between the first and second fenestration frames. The primary mull connector having a first end with a jamb engagement portion and a second end that is free of a jamb engagement portion.