Note: Descriptions are shown in the official language in which they were submitted.
CA 02819875 2016-02-29
,
H8322767CA
LOCKING CARRIER AND MOUNTING ARRANGEMENT FOR TILT SASH
COUNTERBALANCE SYSTEMS
FIELD
[0002]
The present disclosure relates to window balance
assemblies.
More particularly, the invention pertains to window balance
hardware and locking apparatus for balance carriers.
BACKGROUND
[0003]
This section provides background information related to the
present disclosure which is not necessarily prior art.
[0004]
Modern window assemblies in residential, commercial and
industrial buildings may include one or more window sashes that are movable
vertically within a window jamb. Window sashes that move vertically to open
and
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H8322767CA
close often include two or more window balance assemblies. The balance
assemblies urge the window sash upward (i.e., toward an open position for a
lower sash or toward a closed position for an upper sash) to assist a user in
moving the window sash and to retain the window sash at a position selected by
the user.
[0005]
Locking mechanisms to lock the carrier (also known as a
"shoe") in the jamb channels when the sash of a tilt-sash window assembly is
tilted are known in the art. U.S. Pat. No. 5,353,548, entitled "CURL SPRING
SHOE BASED WINDOW BALANCE SYSTEM", issued October 11, 1994 to
Westfall, discloses a window balance system for a tilt-sash window assembly
having a pair of constant force curl springs having curled convolutions
carried by
sash shoes and free end regions mounted in sash shoe channels above the
region of travel of the shoes. The curl tendency of the springs imparts a lift
to the
curled spring convolutions, and the shoes transmit the lift to the sash. The
springs curl into the convolutions as the shoes rise, and the springs uncurl
from
the shoes into the shoe channels when the shoes move downward. A single
annular cam on a receiver in the shoe locks the shoe in the shoe channel when
the sash is tilted outward. The receiver has an opening which receives a pin
or
pivot bar connected to the sash such that when the sash is tilted, the
receiver
rotates with the sash, whereby the cam rotates to separate the two body parts
of
the shoe body such that they bind against the shoe channel to prevent upward
or
downward movement of the shoe while the sash is tilted.
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SUMMARY
[0006] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of its
features.
[0007] The disclosure provides a window balance assembly with an
improved locking carrier mechanism that is actuated by rotation of the pivot
bar
when the window sash is tilted. Cams on the receiver of the mechanism engage
cam followers in the clamshell-type housing of the carrier forcing them apart
outwardly to lock the carrier in the jamb channel of a window assembly and
prevent movement of the carrier in the channel. The receiver incorporates cams
that engage cam follower surfaces in the housing to improve the distribution
of
the locking forces of the carrier in the jamb channel. A dual locking carrier
expands in both the axial and lateral directions to contact both front and
back
surfaces and opposing side surfaces of the jamb channel.
[0008] In one aspect, the disclosure provides a moving coil window
balance assembly for installation in a window assembly having a carrier, a
curl
spring and a mounting bracket. In certain embodiments, the carrier has a
clamshell-type housing and a receiver. The housing has opposing first and
second housing portions and contains the curl spring. The housing includes a
first aperture extending therethrough along a first axis and located proximate
to a
bottom end of the housing. In addition, the housing has arcuate recesses that
at
least partially surround the first aperture, and axial cam followers.
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[0009] The receiver is rotatably engaged in the aperture. The
receiver is a generally cylindrical member including slotted recesses formed
in
each end, and having two symmetric, annular cams extending around a portion
of its perimeter.
[0010] When the receiver is in a first rotational (unlocked)
position,
the cams are received in the recesses and the first and second housing
portions
are closed against one another at the bottom end of the housing. When the
receiver is in a second (locked) rotational position, the cams on the receiver
engage the axial cam followers (e.g., interior faces of the first and second
housing portions) and displace the first and second housing portions away from
one another at the bottom end of the housing in a direction along the first
axis
(e.g., an axial direction).
[0011] In another aspect of the disclosure, the housing includes an
insert comprising a friction enhancing feature that protrudes from an exterior
face
of the housing that is perpendicular to the first axis.
[0012] In still another aspect of the disclosure, the housing
further
includes lateral cam followers. When the receiver is in a second rotational
position, the receiver engages the axial cam followers and displaces the first
and
second housing portions away from one another at the bottom end of the housing
in a direction along the first axis (e.g., an axial direction). In addition,
the receiver
engages the lateral cam followers and displaces the first and second housing
portions away from one another at the bottom end of the housing in a direction
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along a second axis that is generally perpendicular to the first axis (e.g., a
lateral
direction).
[0013] In still another aspect of the disclosure, the first and
second
housing portions include lateral cam followers extending from their interior
faces
adjacent to the first aperture. When the receiver is in a second rotational
position, the cams engage the interior faces of the first and second housing
portions and displace the first and second housing portions away from one
another at the bottom end of the housing in a direction along the first axis,
and
the cams engage the lateral cam followers of the first and second housing
portions and displace the first and second housing portions away from one
another at the bottom end of the housing in a direction along a second axis
that
is generally perpendicular to the first axis.
[0014] In an alternate configuration, an insert is disposed in
second
apertures formed in the first and second housing portions. The insert serves
as a
lateral cam follower and further includes a friction enhancing feature that
protrudes from exterior faces of the first and second housing portions.
[0015] In a still further aspect of the disclosure, the housing has
at
least one opening near the first aperture and a locking pad is mounted in the
opening. The locking pad has a rear cam follower and a forward surface. When
the receiver is in a first rotational position, the locking pad is in a first
retracted
position in the housing. When the receiver is in a second rotational position,
the
cam engages the cam follower of the locking pad and the locking pad is in a
second extended position wherein the forward surface extends from the housing.
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[0016] In
yet another aspect of the disclosure, the mounting bracket
comprises a body portion having a back wall and at least one side wall. A
spring
attachment portion is located at an upper end of the side wall for engaging
the
curl spring. A mounting hook extends from an upper portion of the back wall
and
a tab member extends from a lower portion of the back wall. The mounting
bracket also includes an attachment portion for connecting to the upper end of
the carrier.
[0017]
Further areas of applicability will become apparent from the
description provided herein. The description and specific examples in this
summary are intended for purposes of illustration only and are not intended to
limit the scope of the present disclosure.
DRAWINGS
[0018] The
drawings described herein are for illustrative purposes only
of selected embodiments and not all possible implementations, and are not
intended to limit the scope of the present disclosure.
[0019] FIG.
1 is a partial schematic front view of a window
assembly including window balance assemblies according to the principles of
the
present disclosure;
[0020] FIG.
2 is a partial schematic front view of the window
assembly of FIG. 1 showing a raised and tilted window sash;
[0021] FIG.
3 is a partial schematic side view of the window
assembly of FIG. 2;
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[0022] FIG. 4 is a perspective view of an exemplary window
balance assembly including a locking carrier in an uninstalled configuration
according to the principles of the present disclosure;
[0023] FIG. 5 is a side view of the window balance assembly of
FIG. 4;
[0024] FIG. 6 is an exploded perspective view of the window
balance assembly of FIG. 4;
[0025] FIG. 7 is a partially cut-away perspective view of the
window
balance assembly of FIG. 4 installed in a window jamb according to the
principles
of the present disclosure;
[0026] FIG. 8 is a perspective view of an exemplary carrier
assembly for use with a window balance assembly according to the principles of
the present disclosure having a housing portion removed.
[0027] FIG. 9 is a perspective view of an exemplary receiver for
use
with a window balance assembly according to the principles of the present
disclosure;
[0028] FIGs. 10A through 10D are perspective views of an
exemplary dual locking carrier assembly for use with a window balance assembly
according to the principles of the present disclosure;
[0029] FIG. 11 is an exploded perspective view of the dual locking
carrier assembly of FIGs. 10A¨ 10D;
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[0030] FIGs. 12A, 12B and 12C are perspective views of still
another exemplary dual locking carrier assembly for use with a window balance
assembly according to the principles of the present disclosure;
[0031] FIG. 13A is a perspective view of yet another exemplary dual
locking carrier assembly for use with a window balance assembly according to
the principles of the present disclosure;
[0032] FIG. 13B is a schematic front view of the carrier assembly
of
FIG. 13A;
[0033] FIG. 14A is a perspective view of another exemplary dual
locking carrier assembly for use with a window balance assembly according to
the principles of the present disclosure;
[0034] FIG. 14B is a cross-sectional perspective view of the
locking
carrier assembly of FIG. 14A along the line 14B ¨ 14B;
[0035] FIG. 15 is a perspective view of another locking carrier
assembly for use with a window balance assembly according to the principles of
the present disclosure;
[0036] FIG. 16 is another perspective view of the locking carrier
assembly of FIG. 15;
[0037] FIG. 17 is a cross-sectional view of the locking carrier
assembly of FIG. 16 along the line 17 ¨ 17;
[0038] FIG. 18 is an enlarged, partial perspective view showing the
locking carrier assembly of FIG. 15 and including a friction enhancing
material on
the locking pad;
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[0039] FIG. 19 shows a perspective view of yet another alternative
embodiment of a window balance assembly including a locking carrier in an
uninstalled configuration;
[0040] FIGs. 20A and 20B show orthogonal views of an alternative
mounting bracket of the window balance assembly of FIG. 19;
[0041] FIG. 21 shows a perspective view of still another
alternative
embodiment of a window balance assembly including a locking carrier in an
uninstalled configuration;
[0042] FIGs. 22A and 22B show orthogonal views of another
alternative mounting bracket of the window balance assembly of FIG. 21; and
[0043] FIG. 23 shows a perspective view of the back side of a jamb
channel in which the window balance assemblies of FIG. 19 and 21 are
installed.
[0044] Corresponding reference numerals indicate corresponding
parts throughout the several views of the drawings, as appropriate.
DETAILED DESCRIPTION
[0045] Example embodiments will now be described more fully with
reference to the accompanying drawings.
[0046] With reference to FIGs. 1-3, a window assembly 10 is
provided that may include an upper sash 12, a lower sash 14, a pair of window
jambs 16, a window sill 18, and two or more window balance assemblies 20. In
the particular embodiment illustrated in FIG. 1, the upper sash 12 is fixed
relative
to the window sill 18 (i.e., in a single hung window assembly). However, in
some
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embodiments, the upper sash 12 may be movable relative to the window sill 18
between a raised or closed position and a lowered or open position (i.e., in a
double hung window assembly). The lower sash 14 may be raised and lowered
between open and closed positions and may be connected to the window
balance assemblies 20 which assist a user in opening the lower sash 14 and
maintain the lower sash 14 in a desired position relative to the window sill
18.
[0047] The lower sash 14 may include a pair of pivot bars 22 and a
pair of tilt latch mechanisms 24. The pivot bars 22 may extend laterally
outward
in opposing directions from a lower portion of the lower sash 14 and may
engage
corresponding ones of the window balance assemblies 20, as will be
subsequently described. The tilt latch mechanisms 24 may extend laterally
outward in opposing directions from an upper portion of the lower sash 14 and
may selectively engage corresponding ones of the window jambs 16. The tilt
latch mechanisms 24 may be selectively actuated to allow the lower sash 12 to
pivot about the pivot bars 22 relative to the window jambs 16 to facilitate
cleaning
of an exterior side of the window assembly 10, for example.
[0048] It will be appreciated that in a double hung window
assembly, the upper sash 12 may also be connected to two or more window
balance assemblies to assist the user in opening the upper sash 12 and
maintaining the upper sash 12 in a selected position relative to the window
sill
18. In such a window assembly, the upper sash 12 may also include tilt latches
and pivot bars to allow the upper sash 12 to pivot relative to the window
jambs 16
in the manner described above.
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CA 02819875 2013-06-28
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[0049] Each of the window jambs 16 may include a jamb channel
26 defined by a first wall 28, a second wall 30 opposite the first wall 28,
and third
and fourth walls 32, 34 disposed perpendicular to the first and second walls
28,
30 (FIG. 7). The first wall 28 may include a vertically extending slot 36
adjacent
the lower sash 14. The window balance assembly 20 may be installed within the
jamb channel 26. The pivot bar 22 may extend through the slot 36 and into the
jamb channel 26 to engage the window balance assembly 20. The tilt latch
mechanism 24 may also selectively engage the slot 36 to lock the lower sash 14
in an upright position (FIG. 1).
[0050] The window balance assemblies include a carrier (also
referred to as a shoe), a biasing member that provides the counterbalancing
force against the weight of the window sash, and a mounting bracket that
attaches one end of the balance assembly to the window jamb. Referring to the
figures, in the embodiments shown, balance assemblies 20 may include a carrier
40, a curl spring 42, and a mounting bracket 44. The configuration shown is a
so-called "moving coil" constant force balance assembly; however, other types
of
balance assemblies can employ the locking carrier of this disclosure.
[0051] The window balance assemblies 20 may be initially
assembled and shipped in an uninstalled or shipping configuration (shown in
FIGs. 4 and 5) and may be subsequently installed onto the window assembly 10
and placed in an installed configuration (shown in FIG. 7) by a window
manufacturer, a construction or renovation contractor, or a homeowner, for
example.
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[0052] Referring to FIGs. 6 and 7, the carrier 40 may engage
the
lower sash 14 and house a curled portion 45 of the curl spring 42. The
mounting
bracket 44 may engage an uncurled end portion 47 of the curl spring 42 and may
be fixed relative to the window jamb 16, as shown in FIG. 7. The curl spring
42
may resist being uncurled such that the curl spring 42 exerts an upward force
on
the carrier 40, thereby biasing the lower sash 14 toward the open position.
[0053] Again with reference to FIG. 6, the carrier 40 may
include a
first housing portion 46, a second housing portion 48, and a receiver 50. The
first
and second housing portions 46, 48 may be identical components that fit
together to form a clamshell-type housing for the curl spring 42 and the
receiver
50. Forming the first and second housing portions 46, 48 as identical
components can reduce the total number of different individual components that
must be manufactured and facilitate poka-yoke assembly of the carrier 40. That
is, assembly of the carrier 40 is simplified in that a worker need not be
concerned
with selecting the correct one of each of a pair of different mating
components to
assemble together.
[0054] Each of the first and second housing portions 46, 48
may
include an exterior face 52, an interior face 54, a top end 56, a bottom end
58, a
first side 60, and a second side 62. An aperture 64 disposed proximate the
bottom end 58 may extend through the exterior and interior faces 52, 54 and
may
rotatably engage the receiver 50. Arcuate recesses 65 formed in the interior
face
54 may be concentric with the aperture 64 and may partially surround the
aperture 64. A first slot 66 in communication with the aperture 64 may be
formed
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in the exterior face 52 and may extend vertically upward along the Y-axis
(see,
e.g., FIG. 5) from the aperture 64.
[0055] A barbed protuberance 68 may be disposed at or proximate
to the first side 60 and may extend outward from the interior face 54. A
second
slot 70 may be formed in the second side 62 generally opposite the barbed
protuberance 68 such that when the first and second housing portions 46, 48
are
assembled together, the barbed protuberances 68 may engage the second slots
70 (shown best in FIG. 4). The length of the barbed protuberance 68 may be
sufficient to allow the first and second housing portions 46, 48 to move
relative to
each other between a first unlocked position and a second locked position
without disengaging each other.
[0056] The interior face 54 may include generally cylindrical
recesses 72. When the first and second housing portions 46, 48 are assembled
together, the cylindrical recesses 72 cooperate with each other to form a nest
that receives the curled portion 45 of the curl spring 42. Openings 76 in
communication with the recess 72 may be formed in the first and second sides
60, 62 through which the uncurled portion 47 of the curl spring 42 may extend
toward the mounting bracket 44.
[0057] The first and second housing portions 46, 48 may also
include a projection 80 and a third slot 82 disposed at the top end 56. The
projection 80 may extend from the exterior face 52 beyond the interior face 54
and may include a generally I-shaped cross-section having upper and lower
flanges 84, 86. The third slots 82 may be sized and shaped to enable the third
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slots 82 of the first housing portion 46 and the second housing portion 48 to
slidably engage the lower flanges 86 of the second housing portion 48 and the
first housing portion 46, respectively. In a similar manner, pegs 88 and
apertures
90 formed in the interior face 54 of the first and second housing portions 46,
48
may be sized and positioned to slidably engage each other when the first and
second housing portions 46, 48 are assembled together.
[0058] As
illustrated in FIGs. 6 and 9, the receiver 50 may be a
generally cylindrical member including slotted recesses 92 formed in each end
thereof and have two symmetric, annular cams 94 extending around a portion of
the perimeter of the receiver 50. One of the recesses 92 of each of the window
balance assemblies 20 may receive a corresponding one of the pivot bars 22
extending from the lower sash 14. As described above, the receiver 50 may be
rotatable within the aperture 64 to allow the lower sash 14 to pivot about the
pivot
bar 22 between an upright position and a tilted position. The angular span of
the
cams 94 may correspond to the angular span of the arcuate recesses 65 that
partially surround the aperture 64 in the first and second housing portions
46, 48
such that when the lower sash 14 is in the upright position, the cams 94 fits
within the arcuate recesses 65. As shown, gaps 93 between the cams 94
comprise the generally cylindrical exterior of the receiver 50. Alternatively,
the
cams 94 may be arcuately abridged by thin rib portions (not shown) that do not
engage the arcuate recesses 65 and lie adjacent to the interior faces 54 of
the
first and second housing portions 46, 48.
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[0059] When the receiver 50 is oriented such that the
slotted recess
92 is oriented horizontally relative to the carrier 40 (i.e., along the X-
axis), the
cams 94 may be fully received within the arcuate recesses 65 (see FIGs. 4 and
8). When the cams 94 are received in the arcuate recesses 65, the first and
second housing portions 46, 48 are allowed to fully close together. In this
configuration, the carrier 40 is in an unlocked or unrestricted position, such
that
the carrier 40 may be generally unrestricted from moving upward and downward
in the window jamb 16 as the lower sash 14 moves between the open and closed
positions.
[0060] When the lower sash 14 is tilted relative to the
window jamb
16, the pivot bar 22 rotates the receiver 50 toward the orientation shown in
FIG.
5, in which the slotted recess 92 is oriented vertically (i.e., along the Y-
axis) and
is generally aligned with the first slot 66 in the carrier 40. Rotating the
receiver
50 in this manner moves the cams 94 out of the arcuate recesses 65 and causes
surfaces 95 of the cams 94 to engage portions of the interior faces 54 and
force
the interior faces 54 of the first and second housing portions 46, 48 axially
away
from each other in a direction along the Z-axis. As such, portions of the
interior
faces 54 of the first and second housing portions 46, 48 function as axial cam
followers to the surfaces 95 of the cams 94. In this manner, the exterior
faces 52
of the first and second housing portions 46, 48 are forced against the first
and
second walls 28, 30 of the jamb channel 26. Forcing the exterior faces 52
outward against the first and second walls 28, 30 creates friction that may be
sufficient to lock the carrier 40 in place relative to the jamb channel 26.
CA 02819875 2013-06-28
[0061] Moreover, as shown in FIG. 6, the first and second housing
portions 46, 48 can include apertures 506 that can accommodate optional
inserts
508 to increase the friction for locking the carrier 40 in place. In this
regard, the
inserts 508 are received in the apertures 506 of the housing portions 46, 48,
such
as by an interference or press fit. The inserts 508 include a head portion 512
having an exterior surface 514. When the insert 508 is installed (FIGs. 4 and
5),
the exterior surface 514 of the head portion 512 lies approximately flush with
the
exterior face 52 of the housing portions 46, 48; that is, it can protrude
slightly
from the exterior face 52. The exterior surface 514 can include a friction
enhancing feature 516 to improve the frictional contact between the carrier 40
and the walls 28, 30 of the jamb channel 26 when the carrier 40 is locked in
place. The friction enhancing feature 516 can comprise material or a treatment
to the surface 514 that modifies the coefficient of friction of the exterior
surface
514.
[0062] Accordingly, when the lower sash 14 is in a tilted position,
the window balance assembly 20 may be prevented from exerting a net upward
force on the lower sash 14. The cams 94 and cam followers are preferably
formed to provide full locking engagement with a tilt of the sash of 20
degrees or
less with respect to the vertical position, since as the tilt angle increases,
the
amount of the weight of the sash being supported by the balance decreases such
that the balance may raise the sash if not locked in the balance channel. In
some
embodiments, the rib portions and cam followers are formed to provide full
locking engagement with only a small tilt, for example 5 degrees, of the sash.
In
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other embodiments, full locking engagement occurs at tilt angles greater than
5
degrees.
[0063] including two cams 94 on the receiver 50 engaging two cam
follower surfaces in the housing improves the distribution of the locking
forces
from the exterior faces 52 of the carrier 40 across the surfaces 28, 30 of the
jamb
channel 26 over that of prior art carrier designs having a receiver with a
single
cam, such as that shown in U.S. Pat. No. 5,353,548.
[0064] When the carrier 40 is locked in place within the jamb
channel 26, the lower sash 14 can be removed from the window assembly 10 for
maintenance or replacement, for example. To remove the lower sash 14, the
pivot bars 22 can be removed from the receivers 50 by moving the pivot bars 22
upward out of the slotted recesses 92 and into the first slot 66 in the
carriers 40.
Thereafter, the pivot bars 22 can be removed from the window balance
assemblies 20 so that the lower sash 14 can be removed from the window
assembly 10.
[0065] The opposite procedure may be employed to install the
lower sash 14 into the window assembly 10. That is, with the lower sash 14
tilted
relative to the upper sash 12, the pivot bars 22 may be inserted into the
first slots
66 in the carrier 40 and lowered into engagement with the slotted recesses 92
in
the receivers 50. The lower sash 14 may then be pivoted to the upright
position
relative to the upper sash 12, which includes rotating the receiver 50. As
described above, rotating the receiver 50 allows the first and second housing
portions 46, 48 to fully close together, thereby reducing or eliminating
friction
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between the carrier 40 and the jamb channel 26 to allow unrestricted movement
of the carrier 40 therein.
[0066] Variations of another locking carrier 40' for a tilt-sash
counter
balance assembly and including an improved locking mechanism is shown in
FIGs. 10A ¨ 10D, 11, 12A, and 12B. The carrier 40' provides for locking in
both
the axial (i.e., along the Z-axis) and lateral (i.e., along the X-axis)
directions. The
dual locking carrier 40' is similar to the carrier 40 previously discussed,
and like
features are therefore labeled with like reference numbers, as necessary.
[0067] The dual locking carrier 40', however, includes a lateral
cam
follower 500. For example, a lateral cam follower 500 can extend from the
interior face 54' of each of the first and second housing portions 46', 48'
adjacent
to the aperture 64'. A recess 502 in the interior face 54' is located adjacent
to the
aperture 64' on the side opposite to that of the cam follower 500. In this
manner,
and because first and second housing portions 46', 48' may be identical
components that fit together to form a clamshell-type housing, when the first
and
second housing portions 46', 48' are assembled together, the lateral cam
followers 500 of one of the housing portions may engage the opposed recesses
502 of the other of the housing portions.
[0068] The aperture 64' may rotatably engage the receiver 50'.
Arcuate recesses 65' formed in the interior faces 54' of the first and second
housing portions 46', 48' may be concentric with the aperture 64' and may
partially surround the aperture 64'. As described above, the receiver 50' may
be
rotatable within the aperture 64' to allow the lower sash 14 to pivot about
the
18
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pivot bar 22 between an upright position and a tilted position. The angular
span
of the cams 94' may correspond to the angular span of the arcuate recesses 65'
that partially surround the aperture 64' in the first and second housing
portions
46', 48' such that when the lower sash 14 is in the upright position, the cams
94'
fit within the arcuate recesses 65' and the gaps 93' between the cams 94' are
positioned adjacent to the lateral cam followers 500.
[0069] When the receiver 50' is oriented such that the slotted
recess 92' is oriented horizontally relative to the carrier 40', the cams 94'
may be
fully received within the arcuate recesses 65' (see FIGs. 10A and 10D) and the
first and second housing portions 46', 48' are able to fully close together.
In this
configuration, the carrier 40' is in an unlocked or unrestricted position,
such that
the carrier 40' may be generally unrestricted from moving upward and downward
in the window jamb 16 as the lower sash 14 moves between the open and closed
positions.
[0070] When the lower sash 14 is tilted relative to the window jamb
16, the pivot bar 22 rotates the receiver 50' to lock the carrier, as shown in
FIG.
10(B), in which the slotted recess 92' is oriented vertically and is generally
aligned with the first slot 66' in the carrier 40'. Rotating the receiver 50'
in this
manner moves the cams 94' out of the arcuate recesses 65' and causes the face
surfaces 95' of the cams 94' to force the interior faces 54' of the first and
second
housing portions 46', 48' axially away from each other in a direction along
the Z-
axis. In this manner, the exterior faces 52' of the first and second housing
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=
portions 46', 48' are forced against the first and second walls 28, 30 of the
jamb
channel 26.
= [0071] In addition, however, the same rotation of
the receiver 50'
also causes the outer diameter surfaces 504 of the cams 94' to force the cam
followers 500 of the first and second housing portions 46', 48' laterally away
from
each other in a direction along the X-axis. As such, second sides 62' of the
first
and second housing portions 46', 48' are forced against the third and fourth
walls
32, 34 of the jamb channel 26. As a result, the exterior faces 52' and sides
62'
are forced outward against all four walls 28, 30, 32, 34 of the jamb channel
26 to
create friction that may be sufficient to lock the carrier 40' in place.
[0072] As shown in FIGs. 12A, 12B and 12C, an alternative
configuration of a dual locking carrier 40" is shown. In carrier 40", the
first and
second housing portions 46", 48" may include an aperture 506" in place of a
lateral cam follower. The aperture 506" may accommodate an optional insert
508" which may serve as a cam follower for the outer diameter surface 504 of
the
cam 94". In this manner, the carrier 40" may be easily converted between an
axial locking carrier design and a dual locking carrier design.
[0073] For example, without the insert 508", the carrier 40"
operates
substantially as the carrier 40, with the face surfaces 95" of the cams 94"
engaging the interior faces 54" of the first and second housing portions 46",
48"
when the receiver 50" is rotated, thereby forcing the housing portions 46",
48"
axially outwardly along the direction of the Z-axis. The outer diameter
surfaces
504" of the cams 94", however, do not engage any portion of the first and
second
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,
=
housing portions 46", 48", and therefore do not force the first and second
housing
portions 46", 48" laterally outwardly along the direction of the X-axis.
[0074] With inserts 508" included in the carrier 40",
however, the
carrier 40" operates substantially as the carrier 40'. In this regard, the
inserts
508" are received in the apertures 506" of the housing portions 46", 48", as
shown in FIGs. 12A and 12B, such as by an interference or press fit. As best
illustrated in FIG. 12B, when installed, the exterior surfaces 510" of the
inserts
508" protrude toward the receiver 50". When the receiver 50" is rotated to the
position in which the slotted recess 92" is oriented vertically (i.e., along
the Y-
axis), the outer diameter surfaces 504" of the cams 94" engage the exterior
surfaces 510" of the inserts 508". As such, the inserts 508" serve as cam
followers for the cams 94", forcing the housing portions 46", 48" laterally
outwardly in the direction of the X-axis.
[0075] Moreover, the insert 508" includes a head portion
512" that
includes an exterior surface 514". When the insert 508" is installed, the
exterior
surface 514" of the head portion 512" lies approximately flush with the
exterior
face 52" of the housing portions 46", 48"; that is, it can protrude slightly
from the
exterior face 52". The exterior surface 514" may include a friction enhancing
feature 516" to improve the frictional contact between the carrier 40" and the
walls 28, 30 of the jamb channel 26 when the carrier 40" is locked in place.
The
friction enhancing feature 516" may comprise a material or a treatment to the
surface 514" that modifies the coefficient of friction of the exterior surface
514".
21
CA 02819875 2013-06-28
,
[0076] Still another alternative configuration of a dual locking
carrier
40"' is shown in FIGs. 13A and 13B. In this configuration, side surfaces 62"
of
the housing portions 461", 48" include a friction enhancing feature 518 that
engages the walls 32, 34 of the jamb channel 26 when the carrier 40" is locked
in place. The friction enhancing feature 518 may comprise a material or a
treatment to the side surfaces 62" that modifies the coefficient of friction
of the
side surfaces 62". For example, as shown in FIG. 13B, the friction enhancing
feature 518 may include a plurality of serrations that has the effect of
increasing
the coefficient of friction of the side surfaces 62" that engage the walls 32,
34 of
the jamb channel 26.
[0077] FIGs. 14A and 14B show still another embodiment of a dual
locking carrier design 40" of the disclosure. In the carrier 40", the
clamshell-
type housings 46", 48" each include at one lateral side of the aperture 64" a
cantilevered arm 520 having a cam follower surface 522 and at the opposite
lateral side of the aperture 64" a cam surface 524. When the carrier 40" is
assembled, the cam follower surface 522 of the arm 520 of one housing 46",
48" engages the corresponding cam surface 524 of the other housing 46", 48",
as best seen in FIG. 14B. Then, as the receiver 50" is rotated to the locking
position (as previously described), the housings 46", 48" are forced apart in
a
direction along the Z-axis (also as previously described). This, in turn,
causes
cam surface 524 to force cam follower surface 522, and consequently
cantilevered arm 520, laterally outward in a direction along the X-axis to
achieve
dual locking in both the axial and lateral directions.
22
CA 02819875 2013-06-28
[0078] In yet another embodiment of a locking carrier 320 shown in
FIGs. 15 ¨ 17, one or more locking pads 260, 280 are mounted in an opening in
the carrier 320. The locking pads 260, 280 each have a rearward facing surface
360, 380 forming a cam follower. Each cam follower surface 360, 380 may be
flat or contoured depending on the shape of the cam surfaces of the receiver
140
and the desired locking result. The locking pad 260, 280 has a forward facing
surface extending from the carrier housing 300 in a locked position. A cam
surface 220, 240 of the receiver 140 contacting the cam follower 360, 380
drives
the locking pad 260, 280 to the locked position. The locking pad 260, 280 is
retracted in the carrier 320 in an unlocked position when not driven by the
cam
surfaces 220, 240 of the receiver 140. In some embodiments, the locking pad
260, 280 has a pair of cam followers, each cam follower contacting one of the
cam surfaces of the receiver. The locking pad 260, 280 preferably includes at
least one tab for mounting and maintaining the locking pad in an opening of
the
carrier 320.
[0079] FIG. 15 shows a carrier 320 in an unlocked state. The
locking pads 260, 280 are retracted within the housing 300 of the carrier 320,
because the receiver 140 is oriented with one cam surface 220 upward and
another cam surface 240 downward.
[0080] FIGs. 16 and 17 show the carrier 320 of FIG. 15 in a locked
state. The receiver 140 has been rotated by a quarter turn, or 90 degrees with
respect to the orientation in FIG. 15, corresponding to a 90-degree rotation
of the
sash and pivot bar in an assembled window, such that the cam surfaces 220,
23
p = at w= rxr= +rt,Wrrr r t
,,
CA 02819875 2013-06-28
= ,
=
240 are located squarely behind the two locking pads 260, 280, thereby forcing
the locking pads to extend past the front of the carrier housing 300. In the
locked
state, the locking pads 260, 280 contact the surfaces of the front of the shoe
channel 28, while the back surface of the shoe body 300 contacts the back of
the
shoe channel 30 to bind the carrier 320 in the jamb channel 26 and prevent
upward or downward movement of the carrier 320 and associated sash when the
sash is tilted.
[0081] The front surfaces of the cam surfaces 220, 240 of
the
receiver 140 contact the back surfaces 360, 380 of the locking pads 260, 280,
which serve as cam followers, to drive the locking pads 260, 280 outward from
the carrier housing 300. In FIG. 17, each locking pad 260, 280 is mounted in
the
carrier 320 by a pair of tabs 400, 410 and 420, 430, which preferably fit into
an
opening in the front half 440 of the carrier 320. The tabs 400, 410 and 420,
430
maintain the locking pads 260, 280 in the carrier 320.
[0082] In other embodiments of the present invention, the
locking
pads extend from the back of the shoe to contact the back wall of the shoe
channel. In further embodiments, the back and front of the shoe are symmetric
with a first pair of locking pads extending from the front of the shoe and a
second
pair of locking pads extending from the back of the shoe. In still further
embodiments of the present invention, a single locking pad is contacted by
both
ribs of the cam to extend from the back of the shoe. In other embodiments, a
single locking pad extends from the back of the shoes, and a pair of locking
pads
extends from the front of the shoe.
24
_
f ,a4r
CA 02819875 2013-06-28
[0083] In yet another embodiment, as shown in FIG. 18, one or
more locking pads includes a friction enhancing feature 281, such as a
friction
material that is applied to the contact surfaces of the locking pads 260, 280.
The
friction material can comprise, for example, fiberglass that is suspended in a
resin matrix material that is laminated over the contact surfaces.
[0084] Still other alternative embodiments of a window balance
assembly according to the disclosure are shown in FIGs. 19, 21 and 23. The
window balance assemblies 400 (FIG. 19) and 500 (FIG. 21) may be initially
assembled and shipped in an uninstalled or shipping configuration (shown in
FIGs. 19 and 21) and may be subsequently installed onto the window assembly
(as shown in FIG. 23) and placed in an installed configuration by a window
manufacturer, a construction or renovation contractor, or a homeowner, for
example.
[0085] As previously described, the carrier 40 may engage the
lower sash 14 and house a curled portion 45 of the curl spring 42. The
mounting
bracket 440, 540 may engage an uncurled end portion 47 of the curl spring 42
and may be fixed relative to the window jamb 16. The curl spring 42 may resist
being uncurled such that the curl spring 42 exerts an upward force on the
carrier
40, thereby biasing the lower sash 14 toward the open position.
[0086] As shown in FIGs. 19, 20A and 20B, the mounting bracket
440 for a balance assembly 400 may be formed from a metal material, for
example, and may include a body portion 460 and a lower attachment portion
480. The body portion 460 comprises a planar back wall 481 and two opposed
-
CA 02819875 2013-06-28
=
side walls 482, each projecting from the back wall 481 in a generally
orthogonal
manner. Extending from an upper end of the side wall 482 is a spring
attachment portion 483, upon which uncurled end portion 47 of the curl spring
42
may hook or latch to the mounting bracket 440. The spring attachment portion
483 may extend generally upward and outward (relative to the view shown in
FIG. 22A) from the body portion 460 and may engage an aperture 112 in the
uncurled portion 47 of the curl spring 42. A spring attachment portion 483 can
be
included on either or both of the side walls 482 of the mounting bracket 440,
with
the former arrangement accommodating one of a left-handed or right-handed curl
spring installation in the carrier, and the latter arrangement accommodating
both
left-handed and right-handed curl spring installations in the carrier, as
shown in
FIGs. 20A and 20B.
[0087] Included at an upper end of the body portion 460 is a
mounting hook 484. The mounting hook 484 extends outwardly from the back
wall 481 of the mounting bracket 440 in a direction generally opposite to the
direction in which the side walls 482 project from the back wall 481.
Projecting
outwardly from a lower portion of the back wall 481, but in the same direction
as
the mounting hook 484, is a tab member 485. The mounting hook 484 and tab
member 485 are each operable to engage a corresponding receiving slot 600,
602 in a wall 30 of the jamb channel 16 to co-operably secure the mounting
bracket 440 in position in the jamb channel 16, as best seen in FIG. 23.
[0088] As can be appreciated, installation of the mounting
bracket
440 is achieved by inserting the mounting hook 484 into the upper receiving
slot
26
,
õ
CA 02819875 2013-06-28
600 with the mounting bracket 440 in an orientation generally forming an acute
angle with the jamb channel 16 wall 30. Thereafter, the mounting bracket 440
is
rotated to an orientation generally parallel with the jamb channel 16 wall 30
so
that the tab member 485 is inserted into the lower receiving slot 602. Once
installed, the mounting bracket 440 is secured in the jamb channel 16 against
the
vertical forces applied to the balance assembly 400. Additionally, an optional
mounting aperture 486 may also be included in the body portion 460 of the
mounting bracket 440 and a corresponding fastener may be employed to further
secure the mounting bracket 440 to a jamb wall 30.
[0089] In an uninstalled or shipping configuration, the mounting
bracket 440 is located on top of the carrier 40, where the lower attachment
portion 480 of the mounting bracket 440 connects to the upper end of the
carrier
40. The lower attachment portion 480 of the mounting bracket 440 may include
tapered or curved extension portions 487, 488 that protrude from the back wall
481 and side walls 482 that cooperate with the lower end 489 of the body
portion
460 to slidably engage projections 80 of the carrier 40. In this manner, the
mounting bracket 440 and carrier 40 are joined together when the balance
assembly is in the uninstalled or shipping configuration. Alternatively, a
"break-
away÷ or stress riser feature may be included in the lower attachment portion
480
of the mounting bracket 440 to join the mounting bracket 440 with the carrier
40,
such as disclosed in International application Publication no. WO 2011/100280
entitled, "Window Balance Assembly," which is assigned to the assignee of the
27
CA 02819875 2016-02-29
,
H8322767CA
present disclosure.
[0090] Another alternative window balance assembly 500 is
shown
in FIG. 21, and its associated mounting bracket 540 is shown in FIGs. 22A and
22B. The mounting bracket 540 for a balance assembly 500 may be formed from
a plastic material, such as by molding, for example. In general, the mounting
bracket 540 is similar to the mounting bracket 440, as previously described,
including a body portion 560 and a lower attachment portion 580. The body
portion 560 comprises a planar back wall 581 and two opposed side walls 582,
each projecting from the back wall 581 in a generally orthogonal manner.
Extending from an upper end of the side wall 582 is a spring attachment
portion
583, upon which the curl spring may hook or latch to the mounting bracket 540.
The spring attachment portion 583 may extend generally upward and outward
(relative to the view shown in FIG. 22A) from the body portion 560 and may
engage an aperture 112 in the uncurled portion 47 of the curl spring 42. A
spring
attachment portion 583 can be included on either or both of the side walls 582
of
the mounting bracket 540, with the former arrangement accommodating one of a
left-handed or right-handed curl spring installation in the carrier, and the
latter
arrangement accommodating both left-handed and right-handed curl spring
installations in the carrier.
[0091] Included at an upper end of the body portion 560 is a
mounting hook 584. The mounting hook 584 extends outwardly from the back
wall 581 of the mounting bracket 540 in a direction generally opposite to the
28
_
CA 02819875 2013-06-28
a
direction in which the side walls 582 project from the back wall 581.
Projecting
outwardly from a lower portion of the back wall 581, but in the same direction
as
the mounting hook 584, is a tab member 585. The mounting hook 584 and tab
member 585 are each operable to engage a corresponding receiving slot 604,
606 in a wall 30 of the jamb channel 16 to co-operably secure the mounting
bracket 540 in position in the jamb channel 16, as best seen in FIG. 23. As
can
be appreciated, installation of the mounting bracket 540 is achieved by
inserting
the mounting hook 584 into the upper receiving slot 604 with the mounting
bracket 540 in an orientation generally forming an acute angle with the jamb
channel wall 30. Thereafter, the mounting bracket 540 is rotated to an
orientation generally parallel with the jamb channel wall 30 so that the tab
member 585 is inserted into the lower receiving slot 606. Once installed, the
mounting bracket 540 is secured in the jamb channel 16 against the vertical
forces applied to the balance assembly. Additionally, an optional mounting
aperture 586 may also be included in the body portion 560 of the mounting
bracket 540 and a corresponding fastener may be employed to further secure the
mounting bracket 540 to a jamb wall 30.
[0092] In an uninstalled or shipping configuration, the mounting
bracket 540 is located on top of the carrier 40, where the lower attachment
portion 560 of the mounting bracket 540 connects to the upper end of the
carrier
40. The lower attachment portion 560 of the mounting bracket 540 may include
tapered or curved extension portions 587 that protrude from the back wall 581
that cooperate with the lower end 589 of the body portion 560 to slidably
engage
29
CA 02819875 2016-02-29
H8322767CA
projections 80 of the carrier 40. In this manner, the mounting bracket 540 and
carrier 40 are joined together when the balance assembly is in the uninstalled
or
shipping configuration. Alternatively, a "break-away" or stress riser feature
may
be included in the lower attachment portion of the mounting bracket to join
the
mounting bracket with the carrier.
[0093] The carriers of the window balance assembly are preferably
mountable in either a left jam channel or a right jam channel. To this end,
the
receiver 50 is preferably symmetric so that it can be mounted in either
direction in
the carrier body. The carrier body is also preferably symmetric to the extent
that it
can be oriented in either direction in a jamb channel of a window. When the
balance is a curl spring balance, the carrier is preferably symmetric to the
extent
that the curl spring can be mounted in either orientation in the carrier
housing.
[0094] Although the invention has been described in embodiments
for curl spring window balances, the locking mechanism may be used in any type
of window balances, including, but not limited to, curl spring balances, block-
and-
tackle balances, spiral balances, and hybrid balances. Accordingly, it is to
be
understood that the embodiments of the invention herein described are merely
illustrative of the application of the principles of the invention.
#1447543
