Integrated Window Assembly Mullion Connector Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Window assemblies with metal reinforcement members experience deflection and reduced integrity under wind pressure due to the pivoting or deflecting interfaces between window frames and mullions, leading to potential cracking and reduced stability.
Innovation Solution
An integrated window assembly is designed with a mullion, window frame, and an integrally formed connector, where the reinforcement member is positioned within the mullion's cavity, and the connector engages both the mullion and window frame, using aligned apertures for fastening to secure the assembly and reduce deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fasteners are used to join reinforcement members, window frames, and mullions, then the window assembly can be assembled, but the interfaces between components pivot or deflect under wind pressure causing cracked panes or reduced integrity
Solution Approach 1:
The connector merges the reinforcement member, mullion, and window frame into a single integrated assembly. The connector receives the reinforcement member within its cavity and simultaneously engages the mullion and window frame, creating a unified structure that eliminates relative movement between components under wind pressure.
Solution Approach 2:
The connector is positioned within the cavity of the reinforcement member, which itself is nested within the mullion. This nested arrangement allows the connector to engage multiple components (reinforcement member, mullion, window frame) in a compact configuration, securing them together as a single unit.
2Strength
If metal reinforcement members are used within window frames and mullions to increase strength, then the structural strength is improved, but the assembly becomes more complex and the interfaces still deflect under pressure
Solution Approach 1:
The connector combines multiple fastening functions into a single component that secures the reinforcement member, mullion, and window frame simultaneously. This reduces the number of separate fasteners and assembly steps required, simplifying the overall assembly process while maintaining the strength benefits of metal reinforcement.
Solution Approach 2:
The connector serves multiple functions: it secures the reinforcement member within the mullion, connects the mullion to the window frame, and provides alignment features for accurate assembly. This multi-functionality reduces the need for multiple specialized components, simplifying the assembly process.
3Ease of manufacture
If traditional separate components are used for window frames and mullions, then manufacturing is simpler, but the assembly lacks rigidity and stability when installed
Solution Approach 1:
The connector merges the window frame and mullion into a rigid integrated assembly that resists deflection under wind pressure. By securing these components together with the connector, the assembly achieves the rigidity and stability of a unified structure while maintaining the manufacturing simplicity of separate components.
4Ease of operation
If the window frame and mullion interfaces are allowed to pivot for ease of assembly, then assembly is easier, but the window panes crack or integrity reduces over time
Solution Approach 1:
The connector incorporates alignment features and positioning structures that pre-establish the correct spatial relationship between the window frame and mullion during assembly. This preliminary positioning ensures proper alignment is achieved during assembly, eliminating the need for pivoting or adjustment that would compromise integrity over time.
Data Source
AI summary
Various embodiments of the invention provide an integrated window assembly that includes a mullion, a window frame to be secured relative to the mullion, a reinforcement member positioned within the mullion, sashes on each side of the mullion, and an integrally formed connector positioned between the reinforcement member within the mullion, the window frame, and the sashes. In various embodiments, the integrally formed connector and the reinforcement member provide improved wind resistance for the window assembly, according to various embodiments of the invention. For example, in a particular embodiment, the window assembly can withstand about 75 lbs. per square foot of pressure with no permanent deflection in excess of about 0.4%.