Field of the Invention

The present invention relates to a thermal barrier, and more particularly to a low cost dual plastic pane sealed air unit which does not require a separate frame. Further, the barrier is designed for installation on the inside of an existing window opening and mounts within the existing jamb head and sill on the inside of the existing window which remains in place. With the present invention overall heat transmission, air infiltration by crack leakage and solar heat gain reflects a reduction of 65 to 70 percent and therefore saves 65 to 70 percent of the energy consumed through the opening. Also, the estimated cost of the barrier is such that a pay-back period from energy saved can be realized in about two years .

Description of the Prior Art

Heretofore, various types of thermal barriers or storm windows have been provided , and for example attention is directed to prior U. S. Patents: 4,098,035; 4,040,210; 3 ,911,630; 4,069 ,630; and 4,204 ,015. However, neither of these prior patents or any other known to applicant achieves the advantages that the present invention achieves or accomplishes.

Background and Summary of the Invention

In accordance with the present invention , there is provided retrofit thermal barrier wherein custom window sizes can be constructed with the design and wherein the preferred mode is to manufacture the units for existing stock size window openings and to accomplish the exact fit by the addition of foam tape as required.

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The retrofit thermal barrier is constructed so that condensation is minimized or prevented since the barrier is installed on the inside where the temperature of the barrier will be above the dew point. Further, the barrier is installed on the inside and the barrier is adapted to be made from materials that are readily available from suppliers, and the materials that are used have a long life expectancy.

An object of the present invention is to provide a thermal barrier which is a low cost, dual plastic pane sealed air unit that does not require a separate frame. The barrier is designed for installation on the inside of an existing window opening and mounts within the existing jamb , heat, and sill on the inside of the existing window which remains in place.

Another object of the present invention is to provide a thermal barrier wherein the overall heat transmission, air infiltration by crack leakage, and solar heat gain reflects a reduction of 65 to 70 percent and consequently saves 65 to 70 percent of the energy consumed through the opening. The estimated cost of the barrier is such that a pay-back period from energy can be realized in about two years.

Still a further object of the present invention is to provide a thermal barrier which is comparatively simple in its construction and mode of use, and which is ruggedly constructed and relatively inexpensive to manufacture and efficient to use.

Other objects , features, and advantages of the invention shall become apparent as the description thereof proceeds in connection with the accompanying illustrative drawings.

Brief Description of the Drawings

Figure 1 is an elevational view of a window with the thermal barrier of the present invention installed.

Figures 2A, 2B , 2C and 2D are exploded perspective views showing the steps of fabricating the thermal barrier of the present invention.

Figure 3 is an enlarged sectional view taken on the line 3-3 of Figure 1.

Figure 4 is a fragmentary, elevational view generally taken

*> along the line 4-4 of Figure 3.

Figure 5 is an enlarged sectional view taken on the line 5-5 of Figure 2D .

Description of the Preferred Embodiments

Referring in detail to the drawings, the numeral 10 indicates the retrofit thermal barrier of the present invention which is adapted to be used with a window 11 , Figure 3 , and there is provided the usual head 12 with a similar jamb , and numeral 13 indicates the window sill. The numeral 14 is Figure 3 indicates the existing wall, and there is provided the clear opening 15.

As shown in Figure 2A there is provided a pair of similar rectangular plastic sheets 16 and 17, and each of the sheets 16 and 17 have all four corners cut away as at 18 to provide notches . The upper and lower and side edge portions 19 of the sheets 16 and 17 are adapted to be bent and folded to form a pair of flat pan-shaped members 23 and 24, Figure 2B . The edge portions 19 are folded along the lines 20, Figure 2A. The pair of pan-shaped members

and 24 are adapted to be assembled together to provide a panel or hollow box-like member 21, Figure 2C. Cement 22 is adapted to be used where desired or required such as in the corners of the pan-shaped members 23 and 24, Figure 2B .

As shown in Figure 2C, cellular foam strips 25 are secured to the outer edge portions of the hollow panel 21.

Referring to Figure 2D of the drawings, there is illustrated a method of removing ambient air from the hollow interior of the panel 21 as well as introducing dry air into the interior of the panel. Thus , the fittings 26 and 27 are provided, and these fittings may include suitable needle like members 29 , Figure 5. The fitting 26 can be used for removing ambient air from the interior of the panel, and the other fitting 27 can be used for introducing dry, air into the interior of the panel. A suitable hose, conduit or the like 28 can be used for supplying dry air from a suitable source of supply to the interior of the panel.

Referring to Figure 1 of the drawings, there is illustrated angle clips 30 and 31 which are adapted to be used with the retrofit thermal barrier. The upper clips 30 are spaced inwardly from the surface of the barrier 10, and in addition there is provided a slight amount of space 32, Figure 3 , between the upper clips 30 and the barrier 10 for a purpose to be later described. The lower clips 31 are adapted to abut the lower corner edges of the barrier. In Figure 3 the numeral 33 indicates a space between the barrier 10 and the existing window 11.

From the foregoing it will be seen that there has been provided a retrofit thermal barrier, and in use with the parts arranged as shown in the drawings, the barrier 10 of the present invention is adapted to be made by utilizing the parts previously shown and illustrated. Thus , initially a pair plastic sheets 16 and

17 are provided, and then corner portions of the sheets 16 and 17 are cut away or notched as at 18. Then, edge portions 19 of the sheets 16 and 17 are folded to a right angle position about the fold or crease lines 20 to provide the pair of members 23 and 24 shown in Figure 2B . Figure 2A shows the pair of sheets 16 and 17 with the notched or cut away corners 18. A suitable cement 22 is provided at the corners where desired or required. Next, as shown in Figure 2C, with the pair of members 23 and 24 assembled together to form the hollow panel 21, the cellular foam strips 25 are arranged adjacent the sides and upper and lower edges of the panel 21 , and these cellular foam strips 25 are secured in place to the outer edges of the panel 21 in any suitable manner. Then, as shown in Figure 2D, ambient air is adapted to be withdrawn from the interior of the hollow panel 21 by a suitable fitting 26, and at the same time dry air can be introduced into the interior of the panel as shown in Figure 2D . Figure 5 illustrates in detail a needle-like member 29 that can be used as part of the fitting 26 or 27. With the unit or thermal barrier 10 completed and assembled , the thermal barrier 10 can be installed as shown in Figure 3 so that there will be a space 33 between the thermal barrier 10, and the and the existing window 11. Angle brackets 31 are positioned adjacent to the lower corner portions of the thermal barrer 10, and the lower angle brackets 31 abut the thermal barrier. Upper angle brackets 30 are conveniently arranged at a suitable location, such as inwardly from the side portions of the thermal barrier, and there is provided a light space 32 between the upper angle bracket 30 and the adjacent portion of the thermal barrier 10.

The parts can be made of any suitable material in different shapes and sizes as desired or required.

It will therefore be seen that there has been provided a thermal barrier which is a low cost, dual plastic pane sealed air

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unit that does not require a separate frame. The barrier is designed for installation on the inside of an existing window opening and mounts within the existing jamb, head, and sill on the inside of the existing window which remains in place. In Figure 3, numeral 11 indicates the existing window. The overall heat transmission, air infiltration by crack leakage and solar heat gain reflects a reduction of 65 to 70 percent and consequently saves 65 to 70 percent and consequently saves 65 to 70 percent of the energy consumed through the opening. The estimated cost of the barrier is such that a pay-back period from energy saved can be realized in approximately two years.

When fabricating the barrier, the following is given as a description of the materials that can be used together with the steps for installing the same: .

1. One rectangular sheet l/32"± thickness of appropriate size of polyethelene/acrylic plastic such as sheet 16 can be utilized.

2. One rectangular sheet 17 of 1/32 "± thickness of appropriate size polyethelene/acrylic plastic is adapted to be utilized.

3. On sheet 16, scribe and cut approximately a 1" square corner as at 18 at all four corners .

4. Sheet 16 shall be approximately 1/16" larger in length and width than sheet 17. Heat of approximately 280°F (138°C) to form a flat pan shape of approximately 1" in depth as indicated by the numerals 23 and 24 in Figure 2B .

5. The corners of the pan 23 and 24 are filled with silicone or other compatible cement as at 22 to fill any voids and seal the corners .

6. One pan is slipped over the other pan which creates a box shape as at 21, Figure 2C, with a 1" depth or thickness . The pans 23 and 24 are spot cemented to each other to form a rigid box unit 21.

7. The exposed 1/2" edges of sheets 16 and 17 are cemented to rectangular 25 of the closed cell foam material with stripping tape or contact cement, and the size of the foam is approximately 1" in width by 3/4" in height.

8. The unit is then sealed and contains ambient air.

9. The ambient air is exhausted, as shown in Figure 2D by inserting through the foam 25 and plastic, two needles , such as the needles 29, one for supply or dry air, and one for exhaust of ambient air. After the unit is filled with dry air, the needles are removed and cement is inserted into the foam as required over the needle openings .

10. Next, 1/16" x 1" wide foam mounted on the stripping tape is field supplied to correct for windows which are out of square.

11. The completed barrier can be sized for the specific window opening which is then installed by forcing and compressing the closed cell foam 25 into position and in the window opening, and the barrier is held in position due to tight frictional fit.

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12. The barrier 10 is removed by inserting a thin tool between the joint of the window and the foam to overcome the frictional force.

13. The foam 25 will recover to approximate original dimension of 3/4" upon removal from the opening and ready for re- installation.

14. In the event a set in the foam 25 occurs after considerable time, an additional foam strip may be applied.

The following is given as . certain general comments relative to the barrier of the present invention:

1. Custom window sizes up to 4'-0" by 8'-0" can be constructed with the design, and the preferred mode is to manufacture the units for existing stock size window openings and to accomplish fit by the addition of foam tape as required or desired.

2. The plastic sheets 16 and 17 are bent to form the 90° angle stiffener along the lines 20 so that the bent portions 19 provide the required structured integrity of the barrier.

3. Expansion space is provided by the 3/4" foam stripping 25.

4. The closed cell foam of different polymers exist and are readily available. However, the preferred polymer for the present invention is EPT Polyethylene/Butyl with a density of 2# to 5# per cubic foot. Other polymers

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available are Neoprene, Nitrile, Hydrin, Vinyl Nitrile, and the like.

5. Although any acrylic plastics may be used for the sheeting material, a very thin 4 oz. per square foot or approximately 1/32" thick sheeting is produced by

Plaskalite in Columbus , Ohio. Due to cost and lightweight, the preferred embodiment envisions this material .

6. The sheeting material 16 and 17 may be clear, tinted, or opaque.

7. Condensation is not expected since the barrier 10 is installed on the inside where the temperature of the barrier will be above the dew point.

8. If the cracks in the existing windows are substantial, the barrier may be subject to wind pressure. The pressure on the barrier 10 will be relieved by permitting the top of the barrier to move inward due to wind pressure, a distance equal to the area of the cracks in the existing window by installing two support points or clips 30 inward of the barrier's vertical plane. In Figure 3, the numeral 32 indicates the space provided for this purpose. The bottom of the window is supported in its original position at two points as indicated by the numeral 31.

9. The barrier can be installed in an existing opening with only a 1" jamb-head and sill width.

10. All materials are readily available from suppliers ..

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11. The co-efficient of transmission of the barrier is 0.37.

12. The co-efficient of transmissions of 1/8" glass is 1.13.

13. Materials with a life expectancy of up to ten years proposed to be incorporated into the present invention.

14. The art of bending the plastic sheeting 16 and 17 for structural integrity and the manufacturing process of the barrier can be carried out in a unique and advantageous fashion.

With regard to the members 30, these may be 1" x 1" x 1" long clip angles or recessed spring plungers . A suitable bonding* adhesive can be used for securing the foam 25 to the outer edge portions of the panels 21. Glazing material can be provided for the barrier. The members 25 are in the form of closed seal foam continuous around the entire perimeter. There is provided a sealed air space within the panel or barrier 10, as indicated by the numeral 34. The sealed air space 34 is illustrated in Figure 3.

The members 31 may be 1" x 1" x 1" long clip angles or spring plungers recessed. As shown in Figure 2D , exhaust ports and inflation ports can be provided ^" for the fittings 26 and 27 , and after the fittings or needles are removed these ports can be suitably sealed with cement or the like.

It will be seen that with the present invention there is provided a dead air space, including space 33 between the existing window 11 and the storm window or thermal barrier 10. In addition, there is provided the dead air space 34 within the barrier 10, and this construction provides for maximum insulating properties.

The thermal barrier of the present invention possesses flexibility because the foam 25 can adjust to irregular surfaces quickly and easily, the device is inexpensive to produce and easy to install. The present invention is designed for installation on the inside of an existing window opening the thus reduces the overall heat transmission, air infiltration by leakage and solar heat gain. The present invention can be used as a retrofit or otherwise construction, and the thermal barrier provides important energy consumption savings as previously describing .

While several embodiments of the present invention have been illustrated herein in particular ^' detail, it will be understood that variations and modifications may be effected without departing from the spirit and scope of the novel concepts of this invention.

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