阅读说明：本技术 倒置恒力式窗平衡系统 (Inverted constant force type window balance system ) 是由 威尔伯·詹姆斯·凯勒姆 查德·斯维尔 特拉维斯·斯蒂恩 泰勒·韦尔比格 于 2018-04-06 设计创作，主要内容包括：一种倒置恒力式窗平衡系统,包括承载组件和安装支架。承载组件包括外壳、设置在外壳内的螺旋弹簧以及连接至外壳的滑靴组件。滑靴组件被构造为接收来自窗扇的枢轴杆并在枢轴杆旋转时使至少一个制动块伸出。安装支架与滑靴组件相对地可移除地连接至外壳,并连接至螺旋弹簧的自由端部。安装支架的至少一部分被构造为相对于螺旋弹簧的自由端部在至少两个位置之间滑动地运动。当安装支架的至少一部分在至少两个位置之间运动时,安装支架与外壳脱离并且安装支架与承载组件分离。(An inverted constant force window balancing system comprises a bearing assembly and a mounting bracket. The carrier assembly includes a housing, a coil spring disposed within the housing, and a slipper assembly connected to the housing. The slipper assembly is configured to receive a pivot rod from the window sash and extend the at least one brake shoe upon rotation of the pivot rod. A mounting bracket is removably connected to the housing opposite the slipper assembly and to a free end of the coil spring. At least a portion of the mounting bracket is configured to slidably move between at least two positions relative to the free end of the coil spring. The mounting bracket is disengaged from the housing and the mounting bracket is separated from the carrier assembly when at least a portion of the mounting bracket is moved between at least two positions.)

1. An inverted constant force window counterbalance system comprising:

a carrier assembly, comprising: a housing; a coil spring disposed within the housing, the coil spring including a free end; and a slipper assembly connected to the housing, wherein the slipper assembly is configured to receive a pivot rod from a sash and extend at least one brake shoe upon rotation of the pivot rod; and

a mounting bracket removably connected to the housing opposite the slipper assembly and to the free end of the coil spring, wherein at least a portion of the mounting bracket is configured to slidably move between at least two positions relative to the free end, and wherein the mounting bracket disengages from the housing when the at least a portion of the mounting bracket moves between the at least two positions.

2. The window balancing system of claim 1, wherein the mounting bracket includes a jamb mount and a coil spring mount, wherein the jamb mount is configured to slide relative to the coil spring mount between a first position in which the jamb mount is removably engaged with the housing and a second position in which the jamb mount is disengaged from the housing.

3. The window balancing system of claim 2, wherein the coil spring mount is connected to the free end of the coil spring.

4. The window balancing system of claim 2, wherein the jamb mount comprises a detent and the coil spring mount comprises a corresponding notch defined therein, and wherein the detent is received within the notch in the first position and is disengaged from the notch in the second position.

5. The window balancing system of claim 2, wherein in the first position, the jamb mount is offset from a center of the coil spring mount.

6. The window balancing system of claim 2, wherein the jamb mount comprises at least one elongate arm having a toe extending therefrom, wherein the toe is received by a corresponding projection extending from a top end of the housing when the jamb mount is in the first position.

7. The window balancing system of claim 6, wherein the toe is configured to disengage from the protrusion in the second position to disengage the jamb mount from the housing.

8. The window balancing system of claim 2, wherein the jamb mount comprises a ridge.

9. The window balancing system of claim 1, wherein the slipper assembly includes a housing body having a rotating cam disposed therein, the cam including a cam body having an outer cam surface configured to extend the at least one brake block upon rotation of the cam.

10. The window balancing system of claim 9, wherein the cam further includes a first end and an opposing second end, and wherein a flange extends from the outer cam surface proximate each cam end.

11. The window balancing system of claim 10, wherein the flange extends along an entire perimeter of the outer cam surface.

12. The window balancing system of claim 9, wherein the outer cam surface is defined on a flange extending from the cam body.

13. The window balancing system of claim 9, wherein the at least one brake block includes a substantially U-shaped brake block body having a side and two legs extending therefrom, the brake block body defining a housing opening between the two legs, the housing opening configured to receive the housing body of the slipper assembly such that the at least one brake block is slidably connected to the housing body.

14. The window balancing system of claim 13, wherein each of the legs includes a cam surface configured to be driven by the outer cam surface of the cam body.

15. The window balancing system of claim 9, wherein the housing body is substantially U-shaped and has two legs, each leg including a free end having an extension arm extending therefrom, wherein the extension arm includes a prong.

16. The window balancing system of claim 15, wherein the housing of the carrier assembly includes at least one channel for receipt, the at least one channel having a notch defined in a bottom end portion, the at least one channel configured to receive the respective extender arm of the housing body of the slipper assembly, wherein the notch is configured to receive the lug.

17. The window balancing system of claim 1, wherein the housing of the carrier assembly is a first housing, and the carrier assembly further includes a second housing including a second coil spring disposed therein, the second housing configured to be removably connected between and with the slipper assembly and the first housing.

18. The window balancing system of claim 1, wherein the housing includes an outer wall having at least one longitudinal rib extending therefrom.

19. The window trim system of claim 1, further comprising a baffle configured to be secured at a top end of the housing after the mounting bracket is disengaged from the housing.

20. A mounting bracket for use with an inverted constant force window counterbalance system, the mounting bracket comprising:

a coil spring mount comprising a cage and a rear wall, wherein the coil spring mount is configured to secure a free end portion of a coil spring; and

a jamb mount slidably coupled to the coil spring mount, the jamb mount comprising: two side extension arms configured to slidingly receive at least a portion of the rear wall; and a bottom extension arm including a toe portion configured to engage the housing assembly.

21. The mounting bracket of claim 20, further comprising a ridge located opposite the two side extension arms.

22. The mounting bracket of claim 20, further comprising at least one aperture defined in the jamb mount, wherein a mechanical fuse extends from the at least one aperture.

23. The mounting bracket of claim 20, wherein the side post mount slides between two positions relative to the coil spring mount, and wherein the side post mount is fixed proximate a first side of the coil spring mount in a first position and the side post mount is positioned proximate an opposing second side of the coil spring mount in a second position.

24. The mounting bracket of claim 23, wherein the rear wall includes a notch and at least one of the two side extension arms includes a detent, and wherein the detent is received within the notch to secure the side post mount in the first position.

25. A method for installing an inverted constant force window counterbalance system within a window jamb, the window counterbalance system comprising a mounting bracket removably connected to a carrier assembly having a coil spring disposed therein, the method comprising:

positioning the window balancing system within the window jamb, wherein the mounting bracket is removably connected to the carrier assembly;

securing the mounting bracket to the window jamb, wherein during a securing operation, at least a portion of the mounting bracket slidably moves relative to the free end of the coil spring and toward the window jamb;

substantially simultaneously with the securing operation, detaching the mounting bracket from the carrier assembly such that the carrier assembly is configured to move within the window jamb; and

receiving at least a portion of a pivot rod connected to a sash in the load bearing assembly.

26. The method of claim 25, wherein the mounting bracket includes a side post mount and a coil spring mount, wherein securing the mounting bracket includes sliding the side post mount from a first position to a second position relative to the coil spring mount.

27. The method of claim 25, wherein the mounting bracket includes a toe and the carrier assembly includes a protrusion, wherein detaching the mounting bracket from the carrier assembly includes disengaging the toe from the protrusion.

Background

The upper and lower sliding window assembly comprises one or more movable plates or movable window sashes. These movable sashes typically slide within or along the window jambs and may include one or more counterbalance assemblies or systems mounted in the space between the sash and the jamb to assist in the sliding movement of the sash. Some known sash window assemblies allow the sash to pivot relative to the jamb so that the sash may be tilted inward for cleaning and/or installation/removal purposes. As such, the counterbalance system may include a load bearing assembly that is held in place within the window jamb to prevent retraction of the counterbalance system due to a tilted and/or removed sash.

At least some known inverted constant force window counterbalance systems include a load bearing assembly connected to a sash by a pivot rod. The carrier assembly carries a coil spring having a free end secured to the window jamb passage by a mounting bracket, screw or other element. As the coil spring is released by the sliding motion of the sash, the spring's tendency to rebound creates a contraction force to oppose the weight of the sash. As the sash tilts, the locking element of the carrier assembly projects outwardly, contacting the jamb channel and holding the carrier assembly in place to prevent the coil spring from retracting without the weight of the sash.

Disclosure of Invention

In one aspect, the present technology relates to an inverted constant force window counterbalance system comprising: bearing component and installing support, bearing component includes: a housing; a coil spring disposed within the housing, the coil spring including a free end; and a slipper assembly connected to the housing, wherein the slipper assembly is configured to receive a pivot rod from the sash and extend the at least one brake shoe upon rotation of the pivot rod, a mounting bracket removably connected to the housing opposite the load bearing assembly and connected to the free end of the coil spring, wherein at least a portion of the mounting bracket is configured to slidably move between at least two positions relative to the free end, and wherein the mounting bracket is disengaged from the housing when the at least a portion of the mounting bracket moves between the at least two positions.

In one example, the mounting bracket includes a jamb mount and a coil spring mount, wherein the jamb mount is configured to slide relative to the coil spring mount between a first position in which the jamb mount is removably engaged with the housing and a second position in which the jamb mount is disengaged from the housing. In another example, a coil spring mount is connected to a free end of the coil spring. In yet another example, the jamb mount includes a detent and the coil spring mount includes a corresponding recess defined therein, and wherein the detent is received within the recess in the first position and is disengaged from the recess in the second position. In yet another example, in the first position, the side post mount is offset relative to a center of the coil spring mount. In one example, the jamb mount includes at least one elongate arm having a toe extending therefrom, wherein the toe is received by a corresponding projection extending from a top end of the housing when the jamb mount is in the first position.

In another example, the toe portion is configured to disengage from the projection in the second position to disengage the jamb mount from the housing. In yet another example, the side pillar mounting member includes a ridge. In yet another example, a slipper assembly includes a housing body having a rotating cam disposed therein, the cam including a body having an outer cam surface configured to extend at least one brake pad as the cam rotates. In one example, the cam further includes a first end and an opposing second end, and wherein a flange extends from the outer cam surface proximate each cam end. In another example, the flange extends along the entire perimeter of the outer cam surface.

In yet another example, the outer cam surface is defined on a flange extending from the cam body. In yet another example, the at least one brake pad includes a substantially U-shaped body having a side and two legs extending therefrom, the brake pad body defining a housing opening between the two legs, the housing opening configured to receive the housing body of the slipper assembly such that the at least one brake pad is slidably connected to the housing body. In one example, each leg includes a cam surface configured to be driven by an outer cam surface of the cam body. In another example, the housing body is substantially U-shaped and has two legs, each leg including a free end having an extension arm extending therefrom, wherein the extension arm includes a prong. In yet another example, the carriage assembly housing includes at least one receiving channel having a recess defined in a bottom end portion, the at least one channel configured to receive a corresponding extension arm of the housing body of the slipper assembly, wherein the recess is configured to receive the pawl.

In yet another example, the housing of the carriage assembly is a first housing, and the carriage assembly further includes a second housing including a second coil spring disposed therein, the second housing configured to be removably connected between and with the slipper assembly and the first housing. In one example, the housing includes an outer wall having at least one longitudinal rib extending therefrom. In another example, the window balancing system further includes a baffle configured to be secured to a top end of the housing after the mounting bracket is disengaged from the housing.

In another aspect, the present technology relates to a mounting bracket for use with an inverted constant force window counterbalance system, the mounting bracket comprising: a coil spring mount comprising a cage and a rear wall, wherein the coil spring mount is configured to secure a free end of a coil spring; and a jamb mount slidably connected to the coil spring mount, the jamb mount comprising: two side extension arms configured to slidingly receive at least a portion of the rear wall; and a bottom extension arm including a toe portion configured to engage the housing assembly.

In one example, the mounting bracket further includes a ridge located opposite the two side extension arms. In another example, the mounting bracket further includes at least one aperture defined in the jamb mount, wherein the mechanical fuse extends from the at least one aperture. In yet another example, the side post mount slides relative to the coil spring mount between two positions, and wherein the side post mount is secured proximate a first side of the coil spring mount in a first position and the side post mount is positioned proximate an opposing second side of the coil spring mount in a second position. In yet another example, the rear wall includes a recess and at least one of the two side extension arms includes a detent, and wherein the detent is received within the recess to secure the side pillar mount in the first position.

In another aspect, the present technology relates to a method for mounting an inverted constant force window counterbalance system within a window jamb, the window counterbalance system comprising a mounting bracket removably connected to a carrier assembly, the carrier assembly having a coil spring disposed therein, the method comprising: positioning a window balancing system within a window jamb, wherein a mounting bracket is removably coupled to the carrier assembly; securing a mounting bracket to the window jamb, wherein during a securing operation, at least a portion of the mounting bracket slidably moves relative to the free end of the coil spring and toward the window jamb; substantially simultaneously with the securing operation, detaching the mounting bracket from the carrier assembly such that the carrier assembly is configured to move within the window jamb; and receiving at least a portion of a pivot rod connected to the sash in the load bearing assembly.

In one example, the mounting bracket includes a side post mount and a coil spring mount, wherein securing the mounting bracket includes sliding the side post mount from a first position to a second position relative to the coil spring mount. In another example, the mounting bracket includes a toe portion and the carrier assembly includes a protrusion, wherein detaching the mounting bracket from the carrier assembly includes disengaging the toe portion from the protrusion.

Drawings

There are shown in the drawings examples which are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.

Fig. 1A is a perspective view of a hung window frame assembly.

Fig. 1B is a perspective view of an inverted constant force window counterbalance system.

FIG. 1C is a perspective view of the window balancing system of FIG. 1B installed in a window jamb.

FIG. 1D is a plan view of the installed window balancing system of FIG. 1C.

Fig. 1E-1G are perspective views of a window balancing system in an alternative configuration.

Fig. 2A is a perspective view of a main housing assembly of the window balancing system shown in fig. 1B.

Fig. 2B is an exploded view of the main housing assembly.

Fig. 2C is a cutaway perspective view of the main housing assembly.

Fig. 2D is a cross-sectional view of a detail of the main housing assembly shown in fig. 2C.

Fig. 2E is a cutaway perspective view of another detail of the main housing assembly.

Fig. 2F is an interior view of the main housing assembly.

Fig. 3A is a perspective view of a sub-enclosure assembly of the window balancing system shown in fig. 1E-1G.

Fig. 3B is an exploded view of the sub-housing assembly.

Fig. 3C is a cut-away perspective view of a detail of the sub-enclosure assembly.

Fig. 3D is an interior view of the sub-housing assembly.

Fig. 4A and 4B are perspective views of a mounting bracket of the window balancing system shown in fig. 1B.

Fig. 4C is an exploded view of the mounting bracket.

Fig. 4D and 4E are perspective views of the mounting bracket in a first mounting configuration and a second mounting configuration, respectively.

Fig. 4F and 4G are cross-sectional views of the mounting bracket in a transport configuration and a second mounting configuration, respectively.

Fig. 4H and 4I are cross-sectional views of details of the main housing assembly and the mounting bracket in the transport configuration and the second mounting configuration, respectively.

FIG. 5A is a perspective view of a slipper assembly of the window balancing system shown in FIG. 1B.

FIG. 5B is an exploded view of the slipper assembly.

Fig. 5C is a perspective view of the cam.

Fig. 5D and 5E are front views of the slipper assembly in a locked position and an unlocked position, respectively.

FIG. 6 is an exploded view of another slipper assembly that may be used with the window balancing system shown in FIG. 1B.

FIG. 7 is an exploded view of another slipper assembly that may be used with the window balancing system shown in FIG. 1B.

Fig. 8 is a perspective view of an adapter of the window balancing system shown in fig. 1B.

Fig. 9 is a perspective view of an extension piece of the window balancing system shown in fig. 1B.

Fig. 10 is a perspective view of another inverted constant force window counterbalance system.

Fig. 11A is a perspective view of a top end portion of the window balancing system shown in fig. 10.

Fig. 11B is a cross-sectional perspective view of the tip portion taken along the mating plane P shown in fig. 10.

Fig. 12A is a plan view of two window balancing systems installed in a window jamb.

Fig. 12B is a cross-sectional view of the window balancing system in a shipping configuration, taken along the mating plane P shown in fig. 10.

Fig. 12C is a cross-sectional view of the window balancing system in a first installed configuration taken along section 12C shown in fig. 12A.

FIG. 12D is a cross-sectional view of the window balancing system in a second installed configuration taken along section 12D shown in FIG. 12A.

Fig. 13 is a perspective view of a coil spring mount.

Fig. 14 is a perspective view of the window balancing system shown in fig. 10 in an alternative configuration and disposed within a window jamb.

Figure 15A is a side view of a side post mount.

Fig. 15B is a perspective view of the inverted constant force window counterbalance system of fig. 10 with the jamb mount of fig. 15A disposed within the window jamb.

Figure 16 is a side view of another jamb mount.

Fig. 17A is a perspective view of another inverted constant force window balancing system.

Fig. 17B is an internal view of the window balancing system shown in fig. 17A.

Fig. 17C is a perspective view of the window balancing system shown in fig. 17A in an alternative configuration.

Fig. 18A is a partial perspective view of a portion of the main housing assembly.

Fig. 18B is a plan view of the main housing assembly mounted in the window jamb.

Fig. 19A is a perspective view of a baffle of the window balancing system shown in fig. 10.

Fig. 19B is an exploded perspective view of the baffle.

Fig. 19C is a cross-sectional view of the baffle.

Fig. 20A is a perspective view of another jamb mount.

Fig. 20B is a plan view of the side post mount shown in fig. 20A.

FIG. 21 is a flow chart illustrating an exemplary method of installing a window balancing system.

FIG. 22 is a flow chart illustrating an exemplary method of assembling a slipper assembly.

Detailed Description

The examples of window balancing systems described herein enable a more efficient inverted constant force balancing system for use with a hung window assembly. In various aspects, the window balancing system includes a two-piece mounting bracket that facilitates a more secure connection with the window jamb because one portion thereof is slidably mounted flush with the jamb while maintaining the original position of the coil spring. In addition, the mounting bracket may slide along the top of the window balancing system, thereby enabling the window balancing system to be mounted on either the left or the right side of the sash (or in each opposing jamb channel) without requiring any modification. As such, the window balancing system described herein is not limited to being mounted in a single position or orientation. Furthermore, the removable connection between the mounting bracket and the carrier assembly is robust and reduces undesirable separation during transportation and installation time in the hung window assembly.

Further, the window balancing system described herein is fully modular and thus may be adapted and configured for use with a wide variety of sash weights from many different window manufacturers. The load bearing assembly may be modified to include more than two coils in series to account for these added weights. Additionally, adapters and/or extensions may be included within the load bearing assembly to increase adaptability to conventional window sizes and configurations. Thus, the window balancing system described herein increases the ease of use for the installer and the adaptability to many different sizes of hung window assemblies.

Fig. 1A is a perspective view of a hung window frame assembly 10. A pair of sashes 12, 14 are disposed in vertical alignment with window jambs 16 forming the sides of a window frame 18. Typically, in a single-hung window assembly, upper sash 12 is fixed relative to window frame 18 and lower sash 14 is slidable within window frame 18, while in a double-hung window assembly, both upper sash 12 and lower sash 14 are slidable within window frame 18. To counter the weight of the slidable sash 12 and/or 14 and to assist in sliding the sash 12 and/or 14 vertically within the window frame 18, a window balancing system 20 (shown in fig. 1B) is provided. A window balancing system 20 is mounted within the window jamb 16 and connected to the sashes 12, 14 to form a load path capable of supporting the sashes 12, 14. In this example, the window frame assembly 10 is configured for sliding the window sashes 12, 14 vertically. In alternative embodiments, the frame assembly may be configured for sliding the sash horizontally and may include the window balancing system described herein.

Each sash 12, 14 may also include a tilt latch 19 positioned at the top of the sash and a pivot rod 32 (shown in fig. 1C) extending from the lower portion of the sash. The tilt latch 19 and pivot rod 32 enable the sashes 12, 14 to pivot with respect to the window jamb 16 and to be removed from the window jamb 16 and facilitate sash installation and/or window cleaning. Each pivot rod 32 may be connected to a window balancing system 20, the window balancing system 20 being configured to effect both sliding movement of the sashes 12, 14 and pivoting movement of the sashes 12, 14. Typically, a single window balancing system 20 is mounted on either side of each sash 12, 14 and within the corresponding window jamb 16.

Fig. 1B is a perspective view of an inverted constant force window counterbalance system 20 that may be used with the hung window frame assembly 10 (shown in fig. 1A). The window balancing system 20 includes a main housing assembly 100, a mounting bracket 400, and a slipper assembly 500. The main housing assembly 100 houses a constant force coil spring 102 that includes a free end 106 connected to a mounting bracket 400. As described below with reference to fig. 1C and 1D, the mounting bracket 400 enables the window balancing system 20 to be secured to the window jamb 16.

The window balancing system 20 is shown in a transport configuration 22 in which the top end 104 of the main housing assembly 100 is removably connected to the mounting bracket 400. The transport configuration 22 enables the window balancing system 20 to be transported and installed within a window jamb without undesirably dislodging the mounting bracket 400 from the carrier assembly 24, thereby reducing the likelihood that components may be misplaced and/or lost. In this example, the main housing assembly 100 and the slipper assembly 500 may form the bearing assembly 24. The bottom end 108 of the main housing assembly 100 is removably connected to a slipper assembly 500, the slipper assembly 500 being configured to be secured to a window sash by a pivot rod. The slipper assembly 500 includes a locking system 501 that enables the carrier assembly 24 to be frictionally secured within the window jamb when the window sash is tilted relative to the window frame as described herein. The carrier assembly 24 also connects the window balancing system 20 to the sash for vertical sliding movement 26 of the secondary sash while statically securing the mounting bracket 400 to the window jamb.

Fig. 1C is a perspective view of window counterbalance system 20 installed in window jamb 16. Fig. 1D is a plan view of window balancing system 20 of fig. 1C. Referring to fig. 1C and 1D together, the window balancing system 20 is shown in a mounted configuration 28 within the window jamb 16. In the mounting configuration 28, the mounting bracket 400 is secured to the window jamb 16 by one or more screws or other connecting elements 30 so that the mounting bracket 400 may be separated from the main housing assembly 100. The carrier assembly 24 may be connected to a window sash (not shown) by a pivot rod 32 when the mounting bracket 400 is secured to the window jamb 16. Thus, as the sash makes a vertical sliding motion 26 within the window jamb 16, the coil spring is pulled out and retracted relative to the main housing assembly 100 to counter the weight of the sash and impart a secondary sliding motion 26. The pivot rod 32 is received by the slipper assembly 500 so that the sash may also tilt relative to the window jamb 16, and the pivot rod 32 may rotate within the slipper assembly 500 to actuate the locking system 501.

In this example, the window jamb 16 may be a substantially C-shaped channel, such that the mounting bracket 400 is connected to the rear wall 34 thereof. During installation of the mounting bracket 400 (e.g., securing the mounting bracket 400 to the window jamb 16), the mounting bracket 400 may be detached and released from the top end 104 of the main housing assembly 100. In other examples, when securing the mounting bracket 400 to the window jamb 16, the mounting bracket 400 may remain connected with the main housing assembly 100 until the sash is mounted on the carrier assembly 24, such that the top end 104 of the main housing assembly 100 is separated from the mounting bracket 400 by the weight of the sash. Once the carrier assembly 24, including the main housing assembly 100 and the slipper assembly 500, is separated from the mounting bracket 400, the carrier assembly 24 is in the mounted configuration 28. In the mounting configuration 28, the carrier assembly 24 may undergo telescopic movement 26 axially along the jamb channel relative to the mounting bracket 400, and the force exerted by the coil spring 102 at least partially offsets the weight of the sash as described herein.

When the window sash is tilted relative to the window jamb 16, the pivot rod 32 rotates within the slipper assembly 500 and engages the locking system 501 to extend 36 horizontally within the window jamb 16 and toward the jamb channel's sidewall 38 to secure the carrier assembly 24 in place within the window jamb 16 through a frictional connection. As the tilt movement of the sash removes the weight of the sash from the carrier assembly 24, the engagement of the locking system 501 with the side wall 38 resists the recoil force of the coil spring and prevents the carrier assembly 24 from vertical movement 26 within the window jamb 16. Typically, the coil spring is rated for a predetermined sash weight. As such, for heavier sashes (e.g., due to larger size or greater material density), the window balancing system 20 may be modified and reconfigured to add additional coil springs in series to enable the heavier sash to be supported as required or desired.

Fig. 1E-1G are perspective views of an inverted constant force window counterbalance system in an alternative configuration. The window balancing system 20a shown in fig. 1E includes a first alternative configuration of the mounting bracket 400 and the carrier assembly 24 a. In this example, the carrier assembly 24a includes a primary housing assembly 100 with a primary coil spring 102 and a slipper assembly 500, however, the carrier assembly 24a also includes a secondary housing assembly 300 that houses a secondary coil spring 302. In this example, the secondary housing assembly 300 is connected between the bottom end portion 108 of the primary housing assembly 100 and the slipper assembly 500. The free end 304 of the secondary coil spring 302 is connected to the opening 110 defined in the primary coil spring 102 near its free end, thereby forming a series of coils and being able to counterbalance a heavier window sash. In this example, the height 112 of the main housing assembly 100 is greater than the height 306 of the secondary housing assembly 300, and the spring rate and length of the primary coil spring 102 is substantially equal to the secondary coil spring 302. In an alternative embodiment, the height 112 of the main housing assembly may be equal to the height 306 of the secondary housing. Additionally or alternatively, the primary coil spring 102 may have a different spring rate and/or length than the secondary coil spring 302.

By connecting the secondary coil spring 302 in series with the primary coil spring 102, the spring rate and nominal balance weight of the carrier assembly 24a is increased, thereby enabling operation at larger/heavier sash sizes. However, the window balancing system 20 (shown in FIG. 1B) is configured such that any number of additional sub-enclosure assemblies 300 may be added in series. For example, two additional secondary housing assemblies 300 may be added between the main housing assembly 100 and the slipper assembly 500 to form an additional alternative load bearing assembly 24b shown in fig. 1F. In another example, three additional secondary housing assemblies 300 may be added between the main housing assembly 100 and the slipper assembly 500 to form an alternative load bearing assembly 24c shown in FIG. 1G. Alternatively, any number of secondary housing assemblies 300 may be used in a given carrier assembly 24 as required or desired for a particular application.

In fig. 1F and 1G, the top end 312 of each secondary enclosure assembly 300 may be connected to the bottom end 316 of an adjacent secondary enclosure assembly 300 to form a series of enclosure assemblies. In addition, the free end 304 of each secondary coil spring 302 may be connected to an opening 308 defined in an adjacent secondary coil spring 302 to form a series of coil springs.

Further, the modular construction of the window balancing system (e.g., the main housing assembly 100, the secondary housing assembly 300, the mounting bracket 400, and/or the slipper assembly 500) enables other components to be connected thereto. For example, an adapter 800 (shown in fig. 8), an extender 900 (shown in fig. 9), and/or a baffle 1600 (shown in fig. 19A) may be connected to the main housing assembly 100, the secondary housing assembly 300, and/or the slipper assembly 500 to form other load bearing assembly configurations and to implement additional structures and/or functions as further described herein.

Fig. 2A is a perspective view of the main housing assembly 100 of the window balancing system 20 (shown in fig. 1B). Fig. 2B is an exploded view of the main housing assembly 100. Referring to fig. 2A and 2B simultaneously, the main housing assembly 100 includes a housing 114 that extends in a longitudinal direction 115 parallel to the sliding motion 26 (shown in fig. 1C) when installed. The housing 114 includes a top end 104 having a top wall 116 and a bottom end 108 having a bottom wall 118. The housing 114 also includes a first wall 120 and an opposing second wall 122 and a first end wall 124 and an opposing second end wall 126. The housing 114 defines an internal cavity 128 (shown in fig. 2B) that receives the main coil spring 102. In this example, the housing 114 is formed from two identical members 130, 132 that are connected together, however, in alternative examples, the housing 114 may be formed from any number of members that enables the main housing assembly 100 to function as described herein.

The end walls 124, 126 each define an opening 134, 136, respectively, extending from the first wall 120 to the second wall 122. The free end 106 of the coil spring 102 may extend through the opening 134 of the first end wall and toward the top end 104 of the housing 114 for connection to a mounting bracket. In this example, the free end 106 of the coil spring is substantially T-shaped and has a leg 138 and a cross member 140, with the opening 110 defined adjacent the leg 138. The opening 110 is sized and shaped to correspond with the free end of the secondary coil spring so that it can receive and secure the free end of the secondary coil spring and hold it in place when the secondary housing assembly 300 (shown in fig. 3A) is connected in series to the main housing assembly 100 as described above. In alternative examples, the free end 106 of the coil spring may have any other type of configuration that enables the window balancing system to function as described herein.

The main housing assembly 100 also includes a wiper system 142 that includes support splines 144 having tufted fabric pile 146 protruding therefrom. The scraping system 142 is positioned at the top end 104 of the housing 114 and within the first end wall 124. More specifically, first end wall 124 includes a substantially T-shaped channel 148 defined at top end 104. Channel 148 extends from first wall 120 to second wall 122 such that support spline 144 is slidably received therein. By receiving the support splines 144 within the channels 148, the tufted fabric pile 146 may extend beyond the end wall 124 toward the free end 106 of the coil spring. The channel 148 may also be defined by two opposing inclined surfaces 150, 152 such that the tufted fabric pile 146 may fan out in a V-shape as it extends beyond the first end wall 124.

In new and modified building environments, dirt and debris (e.g., gypsum powder, sawdust, sand, etc.) are common and may be present within the window jamb. Dirt and debris accumulation on the coil spring 102 and within the housing 114 reduces its functionality and makes the attached window sash more difficult to open and close, and may also cause undesirable operating noise as the components slide against each other. As such, the scraping system 142 is positioned adjacent the coil spring 102 to scrape the coil spring during each window sash opening and closing to reduce the accumulation of dirt and debris thereon. In addition, the wiper system 142 reduces the infiltration of outside air through the window jamb.

The free end 106 of the helical spring may be connected to the mounting bracket and enable a balanced support of the opening and closing of the attached sash as described above. Fig. 2A and 2B show the free end 106 of the coil spring extending from the opening 134 of the first end wall and the wiper system 142 extending from the first end wall 124. However, the housing 114 is formed from two identical members 130, 132 and thus includes symmetrical openings 136 in the second end wall 126 and symmetrical channels 151 defined in the second end wall 126. Thus, upon assembly, the free end 106 of the coil spring and the scraping system 142 may alternatively protrude from the second end wall 126.

Fig. 2C is a perspective sectional view of the main housing assembly 100, and fig. 2D is a sectional view of a detail of the main housing assembly 100 shown in fig. 2C. Referring to fig. 2C and 2D together, the cross-section is taken along a plane substantially parallel to end wall 124. In this example, the top receiving element 153 is defined within the top wall 116 of the housing 114. The top receiving member 153 includes a substantially U-shaped channel 154 defined in the top wall 116 that extends from the first wall 120 to the second wall 122. The channel 154 is defined by two opposing side surfaces 156, 158 (shown in fig. 2B) and a bottom surface 160. The side surfaces 156, 158 may each include a protrusion 162 extending from an upper portion of the side surfaces 156, 158 at least partially into the channel 154. The projection 162 includes a bottom surface 164 having a recess 166 defined therein. The projection 162 is positioned substantially midway between the first wall 120 and the second wall 122, and thus the projection 162 includes two symmetrical portions 168, 170 each formed in a respective housing member 130, 132 that are positioned proximate to each other when the housing 114 is assembled. Additionally, the walls 120, 122 of the housing members can each include an extension 155 that protrudes at least partially into the channel 154 such that the channel 154 forms a cavity that receives a portion of the mounting bracket at the top end 104 of the housing 114.

In the transport configuration 22 (shown in fig. 1B), the notches 166 receive and engage corresponding prongs 424 (shown in fig. 4B) extending from the mounting bracket 400 to assist in removably connecting the mounting bracket 400 to the main housing assembly 100, as will be discussed further below. The removable connection of the notches/detents enables a more secure connection between the mounting bracket and the main housing assembly 100 so that the mounting bracket and the main housing assembly 100 do not undesirably separate or disengage from each other during transportation. In addition, the removable connection of the notch/claw also enables the mounting bracket to be more quickly separated from the main housing assembly 100 during installation within the window jamb.

Fig. 2E is a perspective cross-sectional view of another detail of the main housing assembly 100. The cross-section is taken along a plane substantially parallel to end wall 124. In this example, the bottom receiving element 172 is defined within the bottom wall 118 of the housing 114. The bottom receiving member 172 includes at least one channel 174 defined in the bottom wall 118 that extends from the first wall 120 to the second wall 122. The channel 174 is substantially T-shaped (e.g., dog bone shaped) and is defined by an innermost surface 176. The innermost surface 176 includes a notch 178 defined on the surface 176 and positioned approximately at a midpoint between the first wall 120 and the second wall 122. As such, the notch 178 is formed by two symmetrical portions each formed in the respective housing member 130, 132.

The bottom receiving element 172 can removably receive and engage a corresponding top extension element from any other component to help form a carrier assembly, such as carrier assemblies 24, 24a, 24B, and 24c (shown in fig. 1B and 1E-1G). For example, the top extension element may be slid into the bottom receiving element 172 to secure the two components together. More specifically, the notch 178 is sized and shaped to receive and engage a corresponding detent on the top extension element, such as a detent 526 of a slipper assembly (shown in FIG. 5A), a detent 352 of a secondary housing assembly (shown in FIG. 3A), a detent 816 of an adaptor (shown in FIG. 8), or a detent 926 of an extension piece (shown in FIG. 9), to achieve a more secure component connection. By including a notch/detent connection, undesirable separation of components is reduced, for example, during shipping, installation, and/or operation of the window balancing system. In one example, the notch/claw connection enables a more automated installation process in which the robot arm can pick up the window balancing system at one pick-up point without the other components separating.

Fig. 2F is an internal view of the main housing assembly 100 (shown in fig. 2A). The housing of the main housing assembly is formed by two identical housing members 130, 132 placed back-to-back and connected together. As such, the housing members 130, 132 each form a half of the top wall 116 including the top receiving element 153, a half of the bottom wall 118 including the bottom receiving element 172, a half of the first end wall 124 including the opening 134, and a half of the second end wall 126 including the opening 136. First end wall 124 includes a first hook-shaped extension 180 proximate top end 104 and a first recess 182 defined in first end wall 124 proximate bottom end 108. Second end wall 126 includes a second hook-shaped extension 184 proximate bottom end 108 and a second recess 186 defined in second end wall 126 proximate top end 104. Hook-shaped extensions 180, 184 correspond to opposing recesses 182, 186, respectively, such that housing members 130 and 132 may be coupled together. For example, the housing members 130 and 132 may be snap-fit connected by hook-shaped extensions 180, 184 and recesses 182, 186. By using the same housing components, the window balancing system is more efficient in manufacturing and assembly processes. However, in other examples, the housing members may be different, and one member may include features and/or components not included on the other member that enable the housing to function as described herein.

In addition, the top wall 116 also includes a top tab 188 proximate the second end wall 126 and a top recess 190 defined within the top wall 116 proximate the first end wall 124 such that when the housing members 130 and 132 are connected together, the opposing tab 188 is received within the recess 190 and provides a more secure connection. Similarly, the bottom wall 118 also includes a bottom tab 192 proximate the second end wall 126 and a bottom recess 194 defined in the bottom wall 118 proximate the first end wall 124. In alternative examples, housing members 130 and 132 may be connected together by any other connection configuration that enables housing 114 to function as described herein. These projections and recesses, as well as the hook-shaped extensions and recesses, are more clearly shown in fig. 2B, but are not labeled with a reference numeral.

The interior cavity 128 that houses the coil spring 102 is defined by an upper annular surface 196 and a lower annular surface 198. The upper annular surface 196 may include a plurality of radially extending recesses 200 that help reduce the surface friction of the upper annular surface 196 as the coil spring 102 rotates therein. The lower annular surface 198 may include a debris collection portion 202 that helps remove dirt and debris that may accumulate within the housing 114. The debris collection portion 202 includes an opening 204 defined in the walls 120, 122 and an angled surface 206 (shown in fig. 2B) offset from the lower annular surface 198 and positioned at the bottom of the internal cavity 128.

Fig. 3A is a perspective view of a sub-enclosure assembly 300 of the window balancing system 20a-20c (shown in fig. 1E-1G). Fig. 3B is an exploded view of the sub-housing assembly 300. Referring to fig. 3A and 3B simultaneously, the secondary housing assembly 300 includes a housing 310 extending in the longitudinal direction 115. The housing 310 includes a top end 312 having a top wall 314 and a bottom end 316 having a bottom wall 318. The housing 310 also includes a first wall 320 and an opposing second wall 322 and a first end wall 324 and an opposing second end wall 326. The housing 310 defines an internal cavity 328 (shown in fig. 3B) that receives the secondary coil spring 302. In this example, the housing 310 is formed from two identical members 330, 332 that are connected together, however, in alternative examples, the housing 310 may be formed from any number of members that enables the secondary housing assembly 300 to function as described herein.

The end walls 324, 326 each define an opening 334, 336, respectively, extending from the first wall 320 to the second wall 322. The free end portion 304 of the coil spring 302 may extend through the opening 334 of the first end wall and toward the top end 312 of the housing 310 to connect to the main housing assembly 100 or an adjacent secondary housing assembly 300. In this example, the free end 304 of the coil spring is substantially T-shaped, having a leg 338 and a cross member 340, with the opening 308 defined proximate the leg 338. The opening 308 is sized and shaped to correspond to the free end 304 of the secondary coil spring such that it can receive and secure the free end 304 and hold it in place when more than one secondary housing assembly 300 is connected together in series. In alternative examples, free end 304 of the coil spring may have any other type of configuration that enables window balancing system 20 to function as described herein.

Fig. 3A and 3B show the free end portion 304 of the coil spring extending from the opening 334 of the first end wall. However, the housing 310 is formed from two identical members 330, 332 and thus includes symmetrical openings 336 in the second end wall 326. Thus, when assembled, the free end 304 of the coil spring may instead protrude from the second end wall 326.

The secondary housing assembly 300 also includes a top extension element 342 defined within the top wall 314 of the housing 310. In this example, the top extension member 342 includes at least one extension arm 344 that extends from the top wall 314 and spans between the first wall 320 and the second wall 322. Elongate arm 344 is substantially T-shaped (e.g., dog bone shaped) having a leg 346 and a cross member 348. Cross member 348 includes a top surface 350 having a prong 352 extending therefrom. The pawl 352 is positioned approximately midway between the first wall 320 and the second wall 322, and thus the pawl 352 includes two symmetrical portions 354, 356 that are each formed in a respective housing member 330, 332.

The top extension element 342 is removably received and engaged by a corresponding bottom receiving element from any other component to help form a carrier assembly, such as carrier assemblies 24a, 24b, and 24c (shown in fig. 1E-1G). More specifically, the prongs 352 are sized and shaped to receive and engage corresponding notches of a bottom receiving element, such as the notch 178 (shown in fig. 2E) of the main housing assembly or the notch 364 (shown in fig. 3C) of the secondary housing assembly, to achieve a more secure component connection as described herein.

Fig. 3C is a perspective sectional view of a detail of the sub-housing assembly 300. The cross-section is taken along a plane substantially parallel to the end wall 324. In this example, the bottom receiving element 358 is defined within the bottom wall 318 of the housing 310. The bottom receiving member 358 includes at least one channel 360 defined in the bottom wall 318 that extends from the first wall 320 to the second wall 322. The channel 360 is substantially T-shaped (e.g., dog bone shaped) and is defined by an innermost surface 362. The innermost surface 362 includes a notch 364 defined on the surface 362 and positioned approximately at a midpoint between the first wall 320 and the second wall 322. As such, the recess 364 is formed by two symmetrical portions each formed in a respective housing member 330, 332.

The bottom receiving element 358 can removably receive and engage a corresponding top elongated element from any other component to help form a load bearing assembly, such as load bearing assemblies 24a, 24b, and 24c (shown in fig. 1E-1G). More specifically, the recess 364 is sized and shaped to receive and engage a corresponding detent on the top extension element, such as the detent 526 of the slipper assembly (shown in fig. 5A), the detent 352 of the adjacent sub-housing assembly (shown in fig. 3A), the detent 816 of the adaptor (shown in fig. 8), or the detent 926 of the extension (shown in fig. 9), to achieve a more secure connection of the components as described herein.

Fig. 3D is an interior view of the secondary housing assembly 300 (shown in fig. 3A). The housing of the sub-housing assembly is formed by two identical housing members 330, 332 placed back-to-back and connected together. As such, the housing members 330, 332 each form a half of the top wall 314 including the top elongated element 342, a half of the bottom wall 318 including the bottom receiving element 358, a half of the first end wall 324 including the opening 334, and a half of the second end wall 326 including the opening 336. First end wall 324 includes a first hook-shaped extension 366 proximate top end 312 and a first recess 368 defined within first end wall 324 proximate bottom end 316. The second end wall 326 includes a second hook-shaped extension 370 proximate the bottom end 316 and a second recess 372 defined in the second end wall 326 proximate the top end 312. Hook-shaped extensions 366, 370 correspond to opposing recesses 368, 372, respectively, such that housing components 330 and 332 may be coupled together. For example, the housing members 330 and 332 may be snap-fit connected by hook-shaped extensions 366, 370 and recesses 368, 372. By using the same housing components, the window balancing system is more efficient in manufacturing and assembly processes. However, in other examples, the housing members may be different, and one member may include features and/or components not included on the other member that enable the housing to function as described herein.

In addition, the top wall 314 also includes a top protrusion 374 proximate the second end wall 326 and a top recess 376 defined within the top wall 314 proximate the first end wall 324 such that an opposing protrusion 378 is received within the recess 380 and provides a more secure connection when the housing members 330 and 332 are connected together. Similarly, bottom wall 318 also includes a bottom protrusion 378 proximate second end wall 326 and a bottom recess 380 defined within bottom wall 318 proximate first end wall 324. In alternative examples, housing members 330 and 332 may be connected together by any other connection configuration that enables housing 310 to function as described herein. These projections and recesses, as well as the hook-shaped extensions and recesses, are more clearly shown in fig. 3B, but are not labeled with a reference numeral.

An interior cavity 328 that receives coil spring 302 is defined by an upper annular surface 382 and a lower annular surface 384. The upper annular surface 382 may include a plurality of radially extending recesses 386 that help reduce the surface friction of the upper annular surface 382 as the coil spring 302 rotates therein. The lower annular surface 384 may include a debris trap 388 that helps remove dirt and debris that may accumulate within the housing 310. The debris trap 388 includes an opening 390 defined in the walls 320, 322 and an angled surface 392 (shown in fig. 3B) offset from the lower annular surface 384 and positioned at the bottom of the inner cavity 328.

Fig. 4A and 4B are perspective views of a mounting bracket 400 of window balancing system 20 (shown in fig. 1B). Referring to fig. 4A and 4B concurrently, the mounting bracket 400 is in a transport configuration 402 corresponding to the transport configuration 22 (shown in fig. 1B) of the window balancing system 20. In this example, the mounting bracket 400 includes a side post mount 404 and a coil spring mount 406. The side pillar mount 404 includes a substantially rectangular main body 408 that is symmetrical about the longitudinal direction 115. The body 408 defines at least one aperture 410 surrounded by a raised collar 411 that enables a screw or other fastener element to connect the mounting bracket 400 to a window jamb during installation. In some examples, the holes 410 may include counter-sunk holes to enable the use of flat-head screw type fasteners.

On one side of the main body 408, the mounting bracket 400 includes a pair of spaced apart side extension arms 412, 414 for connecting the coil spring mount 406 to the side post mount 404. The side extension arms 412, 414 receive the coil spring mount 406 and enable the side post mount 404 to slide relative to the coil spring mount 406 as further described below. The thickness 416 of the side extension arms 412, 414 and the collar 411 is greater than the thickness 418 of the rest of the body 408 so that the mounting bracket 400 can be mounted flush therewith when secured to a window jamb.

The jamb mount 404 also includes a bottom extension member 420 that extends from the bottom of the body 408. The bottom extension member 420 includes a bottom extension arm 422 having a prong 424 extending therefrom. The bottom extension element 420 is removably received and engaged by a corresponding top receiving element 153 (shown in fig. 2C) of the main housing assembly 100. More specifically, the bottom extension arm 422 and the prongs 424 are sized and shaped to be received within the channel 154 of the main housing assembly and engage the notches 166 (both shown in fig. 2C) to removably connect the mounting bracket 400 to the main housing assembly 100 as described herein.

The coil spring mount 406 includes a body 426 having a rear wall 428 and a cage 430 extending outwardly from the rear wall 428. The rear wall 428 is received by the side extension arms 412, 414 to slidingly couple the side post mount 404 to the coil spring mount 406. The cage 430 includes an opening 432 defined in the main body 426 to receive a free end of a coil spring of the main housing assembly. In this example, the cage 430 includes a front wall 434, with an opening 432 sized and shaped to correspond to the free end 106 of a T-shaped coil spring (shown in FIG. 2B). As such, the free end of the coil spring may pass through the opening 432 and be positioned and secured within the cage 430 rearward of the front wall 434 to connect the coil spring to the mounting bracket 400.

Fig. 4C is an exploded view of the mounting bracket 400. In this example, the top extension arm 412 can receive a top end 438 of the rear wall 428 and the bottom extension arm 414 can receive a bottom end 440 of the rear wall 428 such that the side post mount 404 can slidably move relative to the coil spring mount 406 as discussed further below. Two opposing recesses 436 are defined on the free end of the top side extension arm 412 and two side wall extensions 442 are defined on the coil spring mount 406 that are receivable within the recesses 436 of the top side extension arm during sliding movement of the side pillar mount 404. Bottom end 440 includes a notch 444 defined therein and positioned generally at the midpoint of rear wall 428. The recess 444 is capable of receiving and engaging a corresponding detent 446 (shown in fig. 4G) extending from the bottom extension arm 414. The notches 444 and detents 446 enable the side post mount 404 and coil spring mount 406 to be secured in the transport configuration 402 (shown in fig. 4A and 4B).

Fig. 4D and 4E are perspective views of the mounting bracket 400 in the first mounting configuration 448 and the second mounting configuration 450, respectively. Referring to fig. 4D and 4E together, the window balancing system 20 is typically transported in a transport configuration 22 (shown in fig. 1B) with the mounting bracket 400 in a transport configuration 402 (shown in fig. 4A) and with the jamb mount 404 connected to the main housing assembly 100 and centered relative to the coil spring mount 406. By centering the jamb mount 404 relative to the coil spring mount 406, the window balance system can be easily installed in either a right or left window jamb. That is, either of the walls 120, 122 (shown in fig. 2A) of the main housing assembly 100 may be positioned proximate the rear wall of the window jamb because the jamb mount 404 may be slidably moved in either direction toward the jamb and into the mounting configurations 448, 450.

To mount the jamb mount 404 flush with the window jamb, the jamb mount 404 is slidably moved relative to the coil spring mount 406 to either the first mounting configuration 448 or the second mounting configuration 450 while maintaining the position of the main coil spring. By maintaining the position of the main coil spring, the performance of the window balancing system may be improved because the free end of the coil spring does not twist. In the first mounting position 448 and the second mounting position 450, the side post mount 404 slides to the outer end of the coil spring mount 406 such that the side wall extension 442 is received within the recess 436. In this manner, the coil spring mount 406 is flush with the side extension arms 412, 414, thereby providing a flat mounting surface on the window jamb along with the collar 411.

Fig. 4F and 4G are cross-sectional views of the mounting bracket 400 in the transport configuration 402 and the second mounting configuration 450, respectively. The cross-section is taken along a plane substantially parallel to the rear wall 428 of the coil spring mount 406. Referring to fig. 4F and 4G concurrently, in the transport configuration 402, the side post mount 404 is centered relative to the coil spring mount 406 and the notch 444 receives and engages the detent 446 such that a gap 452 is formed between the top end 438 and the top side extender arm 412. As the mounting bracket 400 moves into the second mounting configuration 450 (or similarly the first mounting configuration) during mounting of the window balancing system onto the window jamb, the jamb mount 404 moves slightly downward in the longitudinal direction 115. As such, the fingers 446 disengage from the recesses 444 and a gap 454 is formed between the bottom end 440 and the bottom extension arm 414. Once the prongs 446 are disengaged, the side column mount 404 may be slid in the direction 456 to the second mounting position 450. Depending on the position of the window balancing system within the window jamb, the jamb mount 404 can also similarly be slid along direction 456 to a first mounting position 448 (shown in fig. 4D). Additionally, as the jamb mount 404 moves in a downward direction, the bottom extension element 420 also separates from the main housing assembly as further described below.

Fig. 4H and 4I are cross-sectional views of details of the main housing assembly 100 and the mounting bracket 400 in the transport configuration 22, 402 and the second mounting configuration 28, 450, respectively. The cross-section is taken along a plane substantially parallel to the end walls 124, 126 (shown in fig. 2A) of the main housing assembly 100. Referring to fig. 4H and 4I together, in the transport configuration 22, 402, the jamb mount 404 is centered relative to the main housing assembly 100 and the bottom extension element 420 is connected to the top receiving element 153 of the main housing assembly. More specifically, the prongs 424 are received and engaged by the protruding notches 166. As the mounting bracket 400 moves into the mounting configuration 28, 450, the jamb mount 404 moves slightly downward in the longitudinal direction 115 and the pawl 424 disengages from the notch 166. The jamb mount 404 is then free to slide in the direction 456 and the pawl 424 may move within the channel 154 to disengage the mounting bracket 400 from the main housing assembly 100. Depending on the position of the window balancing system within the window jamb, the jamb mount 404 can also be similarly slid along direction 456 to the first mounting configuration 448 of the mounting bracket 400 (shown in fig. 4D). The movement between the mounting bracket 400 and the main housing assembly 100 may result from sliding, pivoting, twisting, or a combination of two or more of these movements of one or both components relative to each other.

The cooperation between the notch 444 and the tab 446 (shown in fig. 4F and 4G) and the notch 166 and the tab 424 (shown in fig. 4H and 4I) enables the window balancing system to reduce undesirable separation and disengagement between the mounting bracket 400 and the main housing assembly 100 while in the transport configuration 22, 402. However, the use of the notches 444 and the detents 446 and the notches 166 and the detents 424 for the sash provides for effective disengagement and separation between the mounting bracket 400 and the main housing assembly 100 during installation of the window balancing system onto a window jamb. By including a notch/detent connection, undesirable separation of components is reduced, for example, during shipping and/or installation of the window balancing system. In one example, the notch/claw connection enables a more automated installation process in which the robot arm can pick up the window balancing system at one pick-up point without the other components separating.

Fig. 5A is a perspective view of a slipper assembly 500 of window balancing system 20 (shown in fig. 1B). FIG. 5B is an exploded view of the slipper assembly 500. Fig. 5C is a perspective view of the cam 502 of the slipper assembly 500. Referring also to fig. 5A-5C, the slipper assembly 500 includes a rotating cam 502, a housing 504, and at least one brake shoe 506. The rotating cam 502 and the at least one brake block 506 form a locking system 501 that enables the slipper assembly 500 to engage the window jamb when the sash is tilted. The housing 504 includes a substantially U-shaped body 508 having two legs 510, 512 and a base member 514 extending therebetween. The housing 504 also includes a top extension element 516 extending from the top of each leg 510, 512. The top extension element 516 includes at least one extension arm 518 extending from the top of the legs 510, 512. The elongate arm 518 is substantially T-shaped (e.g., dog bone shaped) having a leg 520 and a cross member 522. The cross member 522 includes a top surface 524 with a prong 526 positioned approximately at a midpoint along the top surface 524 and extending therefrom.

Top extension element 516 is removably received and engaged by a corresponding bottom receiving element from any other component to help form a carrier assembly, such as carrier assemblies 24, 24a, 24B, and 24c (shown in fig. 1B and 1E-1G). More specifically, the prongs 526 are sized and shaped to receive and engage corresponding recesses of a bottom receiving element, such as the recess 178 of a main housing assembly (shown in fig. 2E), the recess 364 of a secondary housing assembly (shown in fig. 3C), the recess of an adapter (shown in fig. 8), or the recess of an extension piece (shown in fig. 9), to achieve a more secure component connection as described herein.

The housing 504 defines a cam opening 528 between the legs 510, 512 and terminating at the base member 514. The cam opening 528 includes an annular surface 530 that corresponds to the shape of the cam 502 such that the housing 504 can receive the cam 502 and enable the cam 502 to rotate therein. An annular cam recess 532 is defined on each side of the body 508 at least partially surrounding the cam opening 528. A top opening 534 is defined between the two opposing substantially parallel surfaces 537, 539 between the legs 510, 512 of the housing. As such, the cam 502 may be connected to the housing 504 by sliding the cam 502 through the top opening 534 between the leg surfaces 537, 539 and into the cam opening 528. In this example, the housing legs 510, 512 are each sufficiently resilient that they can deflect outward to facilitate insertion of the cam 502 along the axial direction 535 (shown in fig. 5D). Additionally, the leg surfaces 537, 539 are substantially flat and free of any protrusions to enable easy insertion of the cam 502. The housing legs 510, 512 each include a brake shoe receiving portion 536 having a reduced thickness proximate the base member 514 to enable the brake shoe 506 to be connected to the housing 504. The brake shoe receiving portion 536 includes a flange 538 opposite the cam opening 528 to slidably retain each brake shoe 506 within the housing 504.

The stop block 506 includes a substantially U-shaped body 540 having two legs 542, 544 extending from a side member 546. The body 540 defines a housing opening 548 between the legs 542, 544 and the side member 546. The housing openings 548 enable the brake block 506 to be coupled to the housing 504 at each brake block receiving portion 536. As such, the legs 542, 544 each include an inward projection 550 extending into the housing opening 548 that can engage the brake shoe receiving portion flange 538 to secure the brake shoe 506 to the housing 504. Each leg 542, 544 also includes a cam recess 552 defined on an exterior of the leg 542, 544 and a braking cam surface 554 defined at a free end of each leg 542, 544. The side member 546 may include a rib 556 that extends the length of the stop 506, which increases the frictional retention of the stop 506 within the window jamb. In other examples, the side members 546 may only have substantially flat braking surfaces without the ribs 556.

Referring now to fig. 5C with continued reference to fig. 5A and 5B, the cam 502 includes a substantially cylindrical body 558 having a keyhole 560 defined therein and extending from a first end 562 to a second end 564. The keyhole 560 is sized and shaped to receive a portion of the pivot rod 32 extending from the window sash. The body 558 includes an outer cam surface 568 defining a perimeter thereof. The outer cam surface 568 may engage the brake cam surface 554 such that rotation of the cam 502 slides the brake shoes 506 outward to a locked position 578 (shown in fig. 5D). The body 558 also includes a flat surface 572 that extends along the length of the cam 502 and is bounded by two cam flanges 574 that project outwardly near each end 562, 564. Cam flange 574 allows cam 502 to be retained in housing 504 and not interfere with brake block 506 as cam 502 rotates. The keyhole 560 can be further defined by two opposing ramped surfaces 576 adjacent the outer cam surface 568 that help guide the pivot rod 32 from the top opening 534 of the slipper housing 504 into the keyhole 560.

Fig. 5D and 5E are front views of the slipper assembly 500 in a locked position 578 and an unlocked position 580, respectively. In the locked position 578, the keyhole 560 is in communication with the top opening 534 of the housing so that the pivot rod can be inserted into and/or removed from the slipper assembly 500. When the cam 502 is in the locked position 578, the outer cam surface 568 rotates into proximity to and engagement with the brake cam surface 554 to cause the brake block 506 to undergo an outward extending motion 582 from the housing 504 to contact the window jamb. This holds the carrier assembly 24 in place against the jamb sidewall 38 (shown in fig. 1D) and limits movement within the window jamb. By engaging the two legs of the brake block 506, the slipper assembly 500 engages both ends of the side member of the brake block 506 to improve retention within the window jamb. In the locked position 578, the cam flange 574 is within the annular cam recess of the housing 504 to prevent the cam 502 from sliding out of the cam opening in a substantially vertical direction. In addition, the cam ramp surface 576 is aligned with the housing 504 to help guide the pivot rod into the keyhole 560 along the axial direction 535.

When the cam 502 is rotated to the unlocked position 580, the outer cam surface 568 is rotated away from and out of engagement with the brake cam surface 554, enabling the brake block 506 to undergo a retracting movement 584 into the housing 504 and out of engagement with the window jamb, thereby allowing the carriage assembly to move vertically within the window jamb. As the cam 502 rotates, the keyhole 560 and the flat surface of the cam 502 are positioned proximate the stop block 506 such that the stop block 506 may move inwardly relative to the housing 504. In the unlocked position 580, the cam flange 574 is within the cam recess 552 of the stop 506 to prevent the cam 502 from sliding out of the cam opening in a substantially vertical direction. In this example, the cam 502 may rotate in either direction within the housing 504 and thus enable the carriage assembly 24 to be mounted on either side of the window jamb as described herein.

FIG. 6 is an exploded view of another slipper assembly 600 that may be used with window balancing system 20 (shown in FIG. 1B). The slipper assembly 600 includes a rotating cam 602, a housing 604, and at least one brake shoe 606. The slipper assembly 600 may receive a pivot rod such that as the window sash tilts from the window jamb, the pivot rod rotates and engages the cam 602. As described in detail above, as the cam 602 rotates, the stop block 606 extends from the housing 604 and locks the slipper assembly 600 within the window jamb. However, in this example, the cam ledge 608 extends from the cylindrical body 610 along substantially the entire circumference of the cam surface 612, thus further reducing the likelihood of the cam 602 sliding out of the cam opening 614 defined in the housing 604 because the cam ledge 608 extends a longer distance. In this example, the cam ledge 608 may extend along a cam surface 612 and a flat surface 616 opposite the keyhole 618. In other examples, the cam ledge 608 may extend only along the cam surface 612. In addition, as with the example of fig. 5A-5E, the cam flange 608 does not interfere with the brake shoe 606 when driven by the pivot rod.

Further, in this example, the cam opening 614 is defined by an annular surface 620 that includes two opposing projections 622, 624 on each housing leg, respectively. The projections 622, 624 are positioned at the ends of the leg surfaces 626, 628 that slide along the leg surfaces 626, 628 as the cam 602 is inserted into the housing 604, as described above. The projections 622, 624 project away from the surfaces 626, 628 to provide a receiving structure that retains the cam 602 within the cam opening 614. In some examples, the tabs 622, 324 may be angled to help guide the pivot rod toward the keyhole 618 of the cam 602.

FIG. 7 is an exploded view of another slipper assembly 700 that may be used with window balancing system 20 (shown in FIG. 1B). The slipper assembly 700 includes a rotating cam 702, a housing 704 and at least one brake shoe 706. The slipper assembly 700 may receive a pivot rod such that as the sash tilts from the window jamb, the pivot rod rotates and engages the cam 702. As described in detail above, as the cam 702 rotates, the stop block 706 extends from the housing 704 and locks the slipper assembly 700 within the window jamb. In this example, however, the cam body 708 is substantially cylindrical and has an outer surface 710. A cam flange 712 extends outwardly from the outer surface 710 at each end 714, 716 of the body 708. Body 708 also includes a recess 718 defined therein to enable cam 702 to pass through housing projections 719 of the housing legs that extend into a top opening 720 of housing 704 and to enable cam 702 to be received in cam opening 722. Because cam flange 712 extends from cylindrical cam body 708, brake shoe leg 724 of brake shoe 706 includes a cam surface 726 that does not have any recesses because cam flange 712 enables direct actuation of brake shoe 706. By including the cam flange 712, the likelihood of the cam 702 sliding out of the cam opening is reduced.

Fig. 8 is a perspective view of an adapter 800 that may be used with window balancing system 20 (shown in fig. 1B). The adapter 800 includes a top elongated member 802 and a bottom receiving member 804. The top extension element 802 is defined on a top wall 806 of the adapter 800. The top elongated member 802 includes at least one arm 808 extending from the top wall 806. The arm 808 is substantially T-shaped (e.g., dog bone shaped) having a leg 810 and a cross member 812. The cross member 812 includes a top surface 814 that may have a prong 816 extending therefrom.

The top extension element 802 is removably received and engaged by a corresponding bottom receiving element from any other component to help form a carrier assembly, such as carrier assemblies 24, 24a, 24B, and 24c (shown in fig. 1B and 1E-1G). More specifically, the prongs 816 are sized and shaped to receive and engage corresponding recesses of a bottom receiving element, such as the recesses 178 (shown in fig. 2E) of the main housing assembly or the recesses 364 (shown in fig. 3C) of the secondary housing assembly, to achieve a more secure component connection as described herein.

The bottom receiving element 804 is defined in the bottom wall 818 of the adapter 800. The bottom receiving element 804 includes at least one channel 820 defined in the bottom wall 818 that is substantially T-shaped (e.g., dog bone shaped) and defined by an innermost surface 822. The innermost surface 822 may include a recess (not shown) defined therein.

The bottom receiving element 804 can removably receive and engage a corresponding top elongated element from any other component to help form a carrier assembly, such as carrier assemblies 24, 24a, 24B, and 24c (shown in fig. 1B and 1E-1G). More specifically, the notch is sized and shaped to receive and engage a corresponding detent on the top extension element, such as a detent 526 of a slipper assembly (shown in fig. 5A) or a detent 352 of an adjacent secondary housing assembly (shown in fig. 3A), to achieve a more secure component connection as described herein.

An adapter 800 may be connected between the secondary housing assembly 300 and the slipper assembly 500 to extend the height of the secondary housing assembly 300. As discussed above in fig. 1E, the height 306 of the secondary housing assembly 300 is less than the height 112 of the primary housing assembly 100. The adapter 800 serves to extend the height of the secondary housing assembly 300 to be equal to the height 112 of the primary housing assembly. Additionally or alternatively, an adapter 800 may be used to connect to the slipper assembly 500 to more securely hold the pivot rod in place. A bottom protrusion 824 may extend from the bottom wall 818 and be positioned within the top opening 534 (shown in FIG. 5B) of the slipper assembly to limit axial movement of the pivot rod away from and away from the cam.

Fig. 9 is a perspective view of an extension 900 that may be used with window balancing system 20 (shown in fig. 1B). The elongate member 900 includes a substantially U-shaped body 902 having a top wall 904 and two elongated legs 906, 908 extending downwardly therefrom. Between the legs 906, 908, an elongated pivot rod opening 910 is defined. Proximate the top wall 904, a sloped surface 912 extends from an outer surface of the body 902, at least further defining an elongated opening 910. The body 902 includes angled surfaces 912 on either side of the extension 900.

The extension 900 also includes a top extension element 914 and a bottom receiving element 916. In this example, the top extension element 914 includes at least one arm 918 extending from the top wall 904. Arm 918 is substantially T-shaped (e.g., dog bone shaped) having a leg 920 and a cross member 922. The cross member 922 includes a top surface 924 that may have a prong 926 extending therefrom.

The top extension element 914 is removably received and engaged by a corresponding bottom receiving element from any other component to help form a carrier assembly, such as carrier assemblies 24, 24a, 24B, and 24c (shown in fig. 1B and 1E-1G). More specifically, the prongs 926 are sized and shaped to receive and engage a corresponding notch of the bottom receiving element, such as the notch 178 (shown in fig. 2E) of the main housing assembly or the notch 364 (shown in fig. 3C) of the secondary housing assembly, to achieve a more secure component connection as described herein.

A bottom receiving element 916 is defined in the free ends of each of the legs 906, 908. The bottom receiving element 916 includes at least one channel 928 defined in the free ends of each of the legs 906, 908 that is substantially T-shaped and defined by an innermost surface 930. The innermost surface 930 may include a recess (not shown) defined therein.

The bottom receiving element 916 can removably receive and engage a corresponding top extension element from any other component to help form a carrier assembly, such as carrier assemblies 24, 24a, 24B, and 24c (shown in fig. 1B and 1E-1G). More specifically, the notch is sized and shaped to receive and engage a corresponding detent on the top extension element, such as a detent 526 of a slipper assembly (shown in fig. 5A) or a detent 352 of an adjacent secondary housing assembly (shown in fig. 3A), to achieve a more secure component connection as described herein.

An extension piece 900 is connected between the main or secondary housing assembly 100, 300 and the slipper assembly 500 to provide an elongated opening 910 that helps receive the pivot rod. Additionally, the extension 900 helps guide the pivot rod to the cam 502 (shown in fig. 5A). The elongated opening 910 is in fluid communication with the top opening and keyhole of the slipper assembly for easier installation of the pivot rod and no elongated window is required. By extending the longitudinal length of the elongated opening 910 that receives the pivot rod, it is easier to accommodate a wider sash size, as the pivot rod may fall into the cam without lengthening the window.

Fig. 10 is a perspective view of another inverted constant force window counterbalance system 1000 that may be used with the hung window frame assembly 10 (shown in fig. 1A). Some features of the window balancing system 1000 are described in the examples set forth above and are not further described. In this example, window balancing system 1000 is shown in a transport configuration 1002 and includes a main housing assembly 1004, a mounting bracket 1006, and a slipper assembly 1008. The slipper assembly 1008 may be any of the slipper assemblies described in fig. 5A-7 and will not be discussed further in this example. The main housing assembly 1004 houses a coil spring 1010 that includes a free end 1012 connected to the mounting bracket 1006. As described further below, the top end 1014 of the main housing assembly 1004 is removably connected to the mounting bracket 1006. The bottom end 1016 of the main housing assembly 1004 is removably connected to the slipper assembly 1008, enabling the window balancing system 1000 to be secured within the window jamb during operation as described herein.

The mounting bracket 1006 includes a side post mount 1022 and a coil spring mount 1024. The jamb mount 1022 includes at least one aperture 1026 that enables a screw or other fastener element to attach the mounting bracket 1006 to the window jamb during installation. The side pillar mount 1022 also includes a bottom extension element 1028 configured to be removably received and engaged by a corresponding top receiving element 1030 of the main housing assembly 1004. As such, the mounting bracket 1006 is removably connected to the main housing assembly 1004. The coil spring mount 1024 includes a body 1032 configured to receive a free end 1012 of the coil spring 1010 such that the mounting bracket 1006 is coupled to the coil spring 1010.

In this example, the main housing assembly 1004 may be formed from two identical housing members 1034, 1036 joined at a mating plane P. In the transport configuration 1002, the side pillar mounts 1022 are positioned proximate the first housing component 1034 such that the side pillar mounts 1022 are eccentric relative to the main housing component 1004. When the window counterbalance system 1000 is installed by abutting the first housing member 1034 to the window jamb surface, the jamb mount 1022 is secured to the window jamb such that the top receiving element 1030 does not immediately separate from the bottom extension element 1028. Once the window sash is loaded on the slipper assembly 1008, the top receiving element 1030 moves relative to the bottom extension element 1028 and the main housing assembly 1004 is separated from the mounting bracket 1006. The movement of the top receiving element 1030 may be sliding, pivoting, twisting, or a combination of two or more of these movements. This forms a first mounting configuration (described further below with reference to fig. 12C) such that the main housing assembly 1004 can slide up and down within the window jamb and relative to the mounting bracket 1006. Additionally, when the side pillar mount 1022 is secured to the window side pillar, the side pillar mount 1022 substantially maintains its position on the coil spring mount 1024. I.e., adjacent to its first side 1035, as shown in fig. 10.

When the window counterbalance system 1000 is mounted on the window jamb surface by the second housing member 1036, the jamb mount 1022 is secured to the window jamb such that it moves from a position proximate the first housing member 1034 to a position proximate the second housing member 1036 and across the mating plane P. This movement of the side pillar mount 1022 separates the top receiving member 1030 from the bottom extension member 1028. The movement of the side pillar mounts 1022 may be sliding, pivoting, twisting, or a combination of two or more of these movements. This results in a second mounting configuration (described further below with reference to fig. 12D) in which the main housing assembly 1004 is able to slide up and down in a vertical direction within the window jamb relative to the mounting bracket 1006. Additionally, as the side post mounts 1022 slide from the first housing member 1034 toward the second housing member 1036, the side post mounts 1022 also slide from the first side 1035 of the coil spring mount 1024 to the second side 1037 of the coil spring mount 1024. While the jamb mount 1022 slides across the mating plane P, the coil spring mount 1024 remains centered relative to the main housing assembly 1004.

Similar to the alternative configuration of the window balancing system 20 shown in fig. 1E-1G, the window balancing system 1000 may be connected to one or more secondary housing components such that the spring rate and the rated balance weight of the window balancing system may be increased as required or desired to enable operation at larger/heavier sash sizes. For example, the alternative configuration shown in FIG. 14 includes a secondary housing assembly 1086 connected between the main housing assembly 1004 and the slipper assembly 1008. Additionally, the main housing assembly 1004, the slipper assembly 1008, and any secondary housing assembly form a carrier assembly 1039 configured to be secured to a window sash as described herein.

Fig. 11A is a perspective view of a top end 1014 of the main housing assembly 1004 of the window balancing system 1000 (shown in fig. 10). Fig. 11B is a cross-sectional perspective view of tip portion 1014 taken along mating plane P (shown in fig. 10). Referring to fig. 11A and 11B concurrently, the main housing assembly 1004 is formed from a first housing member 1034 coupled to a second housing member 1036. The top end 1014 of the main housing assembly 1004 includes a top receiving element 1030 configured to receive a portion of a mounting bracket as described above.

The top receiving element 1030 includes a substantially U-shaped channel 1038 (when viewed in cross-section in fig. 11B) defined in the top end 1014. The channel 1038 is defined by two opposing side surfaces 1040, 1042 and a floor surface 1044. The channel 1038 may be bounded by two end walls 1046, 1048, but in other examples, the channel 1038 may be open at one end or both ends. The sole plate surface 1044 may include a sole plate inclined surface 1049. The side surfaces 1040, 1042 may each include a protrusion 1050 that extends at least partially into the channel 1038 generally above and opposite an uppermost portion of the floor inclined surface 1049. The protrusion 1050 is offset from the base plate surface 1044 and includes a protrusion inclined surface 1052 opposite the base plate surface 1044 and the base plate inclined surface 1049. The base plate inclined surface 1049 and the tab inclined surface 1052 are configured to engage spaced apart portions of the mounting bracket to hold the mounting bracket in place when the window balancing system is in a transport configuration as described below. The protrusion 1050 also includes a sloped surface 1054. The ramped surfaces 1054 are configured to assist the mounting bracket in sliding relative to the protrusion 1050 when the mounting bracket is slid from a position proximate to the first housing member 1034 to a position proximate to the second housing member 1036 (i.e., a second mounting configuration, as described below). Since the first housing member 1034 and the second housing member 1036 are identical to each other, the above-described features are present on both the first housing member 1034 and the second housing member 1036.

The ramp 1056 extends from the top end 1014 of the main housing assembly 1004. The ramp 1056 is configured to engage a corresponding surface on the jamb mount to hold the mounting bracket in place when the window trim system is in a transport configuration. The ramp 1056 is positioned opposite the protrusion 1050 and may be formed from ramp portions 1056a, 1056b from the first and second housing members 1034, 1036.

Fig. 12A is a plan view of two window balancing systems 1000a, 1000b installed in a window jamb 1057. When first housing member 1034 is proximate to the window jamb mounting surface, window counterbalance system 1000a is in a first mounting configuration 1070 (described below with reference to fig. 12C). When the second housing member 1036 is adjacent to the window jamb mounting surface, the window balancing system 1000b is in a second mounting configuration 1072 (described below with reference to fig. 12D).

Fig. 12B is a cross-sectional view of the window balancing system 1000 in a transport configuration 1002 taken along a mating plane P (shown in fig. 10). The side pillar mount 1022 includes a bottom extension element 1028 that is shaped and dimensioned to engage with a top receiving element 1030 of the main housing assembly 1004. The bottom extension member 1028 includes a bottom extension arm 1058 having a prong extending therefrom. The pawl may be formed as a toe portion 1060 having two inclined surfaces 1062, 1064. In this example, the top inclined surface 1062 may correspond to the protrusion inclined surface 1052 of the protrusion 1050. The side pillar mount 1022 also includes a ramp surface 1066 that corresponds to a ramp 1056 extending from the main housing assembly 1004.

In operation, free end 1012 of coil spring 1010 is coupled to mounting bracket 1006 at coil spring mount 1024. Coil spring 1010 produces a pull-down force at coil spring mount 1024. As such, the side post mount 1022 is angled toward the coil spring mount 1024. This tilting motion frictionally engages the top inclined surface 1062 of the toe 1060 with the lug inclined surface 1052 of the lug 1050, thereby counteracting and counteracting the tilting motion. In addition, the heel 1068 of the bottom extension arm 1058 engages the bottom plate angled surface 1049 while the ramp surface 1066 frictionally engages the ramp 1056. Thus, in this transport configuration 1002, the side pillar mounts 1022 are secured to the main housing assembly 1004.

Fig. 12C is a cross-sectional view of the window balancing system 1000a in a first installed configuration 1070 and taken along section 12C shown in fig. 12A. When the window counterbalance system 1000a is mounted on the window jamb surface by the first housing member 1034, the jamb mount 1022 is secured to the window jamb such that the bottom extension element 1028 does not separate from the top receiving element 1030. However, once the window sash is loaded on the slipper assembly 1008, the top receiving element 1030 moves relative to the bottom extension element 1028 and the main housing assembly 1004 separates from the mounting bracket 1006. This forms a first mounting configuration 1070. More specifically, the weight of the window sash causes the top receiving element 1030 to move M in a downward sloping direction away from the bottom extension element 1028. This motion may come from sliding, pivoting, twisting, or a combination of two or more of these motions of the main housing assembly 1004 relative to the mounting bracket 1006. This movement M overcomes the toe 1060 engaged with the protrusion 1050 so the main housing assembly 1004 is free to move in a downward sloping direction and away from the mounting bracket 1006.

In this example, toe 1060 does not deform when bottom extension element 1028 is disengaged from top receiving element 1030. After toe 1060 disengages from protrusion 1050, channel 1038 is sized to allow bottom extension element 1028 to clear as main housing assembly 1004 moves. For example, the width of the bottom extension arm 1058 can be about the width of the channel 1038. After the main housing assembly 1004 is separated, it can then be slid up and down within the window jamb relative to the mounting bracket 1006. Additionally, when the side pillar mount 1022 is secured to the window side pillar, the side pillar mount 1022 substantially maintains its position on the coil spring mount 1024. I.e., proximate its first side 1035, as shown in fig. 12A.

Fig. 12D is a cross-sectional view of the window balancing system 1000b in the second mounting configuration 1072, taken along the section 12D shown in fig. 12A. When the window counterbalance system 1000b is mounted on the window side post surface by the second housing member 1036, the side post mount 1022 is secured to the window side post such that it spans from a position proximate the first housing member (rearward of the second housing member 1036 in fig. 12D) to a position within the channel 1038 proximate the second housing member 1036. This horizontal movement of the side pillar mount 1022 separates the bottom extension element 1028 from the top receiving element 1030 and forms a second mounting configuration 1072. More specifically, the movement of the jamb mount 1022 moves the toe portion 1060 substantially orthogonally and out from under the projection 1050 of the first housing member 1034 (shown in the background of fig. 12D) so that the main housing assembly 1004 may move freely in a downward direction and away from the jamb mount 1022. This movement may result from sliding, pivoting, twisting, or a combination of two or more of these movements of the mounting bracket 1006 relative to the main housing assembly 1004.

In this example, as the bottom extension arm 1058 moves from the first housing member 1034 toward the second housing member 1036, the sloped surface 1054 (shown in fig. 11A and 11B) enables the bottom extension arm 1058 to move along the protrusion 1050 without interference. The main housing assembly 1004 is thus able to slide up and down within the window jamb relative to the mounting bracket 1006. For example, the width of the bottom extension arm 1058 can be about the width of the channel 1038. Additionally, as the side post mount 1022 moves from the first housing member toward the second housing member 1036, the side post mount 1022 also slides from the first side of the coil spring mount 1024 to the second side of the coil spring mount 1024. As shown in fig. 12A, the coil spring mount 1024 remains centered relative to the main housing assembly 1004 despite the sliding of the jamb mount 1022 across the mating plane P.

Fig. 13 is a perspective view of a coil spring mount 1024 of the window balancing system 1000 (shown in fig. 10). The coil spring mount 1024 includes a body 1032 having a rear wall 1074 and a cage portion 1076 extending from the rear wall 1074. The body 1032 extends between the first side 1035 and the second side 1037 of the coil spring mount 1024. The rear wall 1074 is configured to be received by the side pillar mount 1022 (shown in fig. 10) such that the side pillar mount 1022 can slide horizontally therealong. The bottom 1078 of the rear wall 1074 may include recesses 1080 and/or detents 1082 defined therein. The recesses 1080 and/or the detents 1082 are configured to engage with corresponding detents and/or recesses defined on the side pillar mount 1022 to help secure the mounting bracket in the transport configuration as described above. In this example, the recess 1080 and/or the prong 1082 may be positioned proximate the first side 1035 of the body 1032 and off-center such that the mounting bracket is secured in the transport configuration.

The coil spring mount 1024 may be made of a metallic material (e.g., zinc die cast, etc.). This achieves a more permanent connection between the helical spring and the mounting bracket and reduces wear of the helical spring on the mounting bracket. In addition, wear on the mounting bracket is reduced in the event of uncontrolled retraction of the counterbalance system within the window jamb (e.g., retraction of the carrier assembly toward the mounting assembly in the event of an unattached sash).

Fig. 14 is a perspective view of an inverted constant force window counterbalance system 1000 (shown in fig. 10) in an alternative configuration 1084 and disposed within a window jamb 1057. In this example, the main housing assembly 1004 is connected to the sub-housing assembly 1086 as described in detail above in fig. 3A-3D. The window jamb 1057 can be a substantially C-shaped channel having a rear wall 1088, two opposing side walls 1090, and two front walls 1092, each of which extends from a respective side wall to define a front open slot 1094. When the window counterbalance system 1084 is installed within the window jamb 1057, the jamb mount 1022 is configured to be secured to the rear wall 1088 by one or more fasteners (not shown) extending through the apertures 1026. The front wall 1092 surrounds the window counterbalance system 1084 to prevent it from moving out of the window jamb 1057.

When the window counterbalance system 1084 is installed within the window jamb 1057 and supports the sash, the weight of the sash is supported by the load path through the window counterbalance system 1084 and into the window jamb 1057. For example, the load path within the window balancing system 1084 includes the slipper assembly 1008 connected to the sash by a pivot pin (not shown), the housing assemblies 1004, 1086, the coil spring, and the mounting bracket 1006 connected to the window jamb 1057 by one or more fasteners (not shown, but through the holes 1026). The connection between the coil spring and the mounting bracket 1006 is offset from the longitudinal axis 1096 of the window counterbalance system 1084 (e.g., the free end 1012 of the coil spring 1010 and the coil spring mount 1024 shown in fig. 10). This offset causes rotational movement R of mounting bracket 1006. That is, the top portion 1098 of the side pillar mount 1022 rotates in a direction toward the coil spring mount 1024 and the bottom portion 1100 of the side pillar mount 1022 rotates in an opposite direction and away from the coil spring mount 1024. Thus, the longitudinal axis 1102 of the mounting bracket 1006 is rotated to an angularly offset position θ relative to the longitudinal axis 1096 of the carriage assembly.

This rotational movement R caused by the load path through the window balance system 1084 can increase wear on the mounting bracket 1006. For example, wear on the connection between the coil spring and the coil spring mount, wear on the connection between the coil spring mount and the side pillar mount 1022, and wear on the connection between the side pillar mount 1022 and the window side pillar 1057. In addition, the rotational movement may increase the likelihood that the free end of the coil spring will disengage from the coil spring mount and disrupt the load path through the window counterbalance system 1084. Accordingly, the mounting bracket, described further below, is configured to reduce rotational movement caused by the load path through the window counterbalance system 1084.

Fig. 15A is a side view of a jamb mount 1200 for use with a window balancing system 1000 such as those shown in fig. 10. The side pillar mount 1200 includes a substantially rectangular body 1202. The body 1202 defines two apertures 1204 surrounded by a collar 1206. The holes 1204 enable screws or other fastening elements to connect the jamb mount 1200 to a window jamb for installation. A collar 1206 is also provided on the opposite surface of the jamb mount 1200 and enables the jamb mount 1200 to be mounted flush against the rear wall of the window jamb. On one side of the body 1202, the side pillar mount 1200 includes a pair of spaced apart side extension arms 1208, 1210 for slidably connecting a coil spring mount 1024 (shown in fig. 10) to the side pillar mount 1200. The side extension arms 1208, 1210 are positioned proximate the top 1212 of the body 1202 and the bottom 1214 of the body 1202, respectively.

On the other side of the body 1202, opposite the side extension arms 1208, 1210, a protuberance 1216 extends from the body 1202 and is disposed proximate the bottom 1214. The ridge 1216 is configured to contact a sidewall of the window jamb. Rotational movement R caused by the load path of the window balancing system may be reduced or eliminated by contact between the ridge 1216 and the window jamb. Further, by providing the ridge 1216 only at the bottom 1214 of the body 1202, the amount of material used to form the side pillar mount 1200 is reduced, thereby saving weight and material costs. In addition, because neither side of the body 1202 extends to the side wall of the window jamb, the window trim system is easier to install within the window jamb because the gap is formed by the ridge 1216.

In addition, the top side extension arm 1208 extends a greater distance from the body 1202 than the bottom side extension arm 1210. As such, the top side extender arm 1208 may also be configured to contact the side wall of the window jamb to reduce rotational movement of the jamb mount 1200. As shown, the protuberances 1216 are opposite and opposite (e.g., bottom to top and right to left) the top side extension arm 1208 such that they are each in the direction of rotational movement R of the side pillar mount 1200. Thus, the protuberance 1216 and the topside extension arm 1208 may contact opposing sidewalls of the window jamb.

The side pillar mount 1200 also includes a bottom elongate member 1218 extending from the bottom 1214 of the body 1202. The bottom extension element 1218 includes a bottom extension arm 1220 having a toe 1222 protruding therefrom to removably connect the jamb mount 1200 to the main housing assembly as described above. Additionally, as described above, the ramp surface 1224 may be formed on the bottom 1214 of the side pillar mount 1200.

Fig. 15B is a perspective view of the inverted constant force window counterbalance system 1000 (shown in fig. 10) with the jamb mount 1200 (shown in fig. 15A) disposed within the window jamb 1057. As described above, the connection between the coil spring and the mounting bracket is offset from the longitudinal axis 1096 of the window counterbalance system 1000 (e.g., the free end 1012 of the coil spring 1010 and the coil spring mount 1024 shown in fig. 10) and causes the rotational movement R of the mounting bracket. However, due to the ridge 1216 described above in fig. 15A, rotational movement R of the mounting bracket 1006 is prevented such that the longitudinal axis 1102 of the side post mount 1200 remains aligned with the longitudinal axis 1096 of the carrier assembly. By limiting rotational movement of the side pillar mount 1200 via the bump, wear on the mounting bracket 1006 is reduced.

Fig. 16 is a side view of another jamb mount 1300 for use with window balancing system 1000 (shown in fig. 10). Certain components are described above and are therefore not further described. In this example, the side pillar mounting member 1300 may include a mechanical fuse 1302 positioned at a bottom 1304 of a body 1306. The mechanical fuse 1302 protrudes from the lower hole 1308 toward the outside of the main body 1306. The mechanical fuse 1302 is configured to sever, for example, during a mechanical overload while securing the jamb mount 1300 to a window jamb via a fastener. When the body 1306 is severed along the mechanical fuse 1302, the opposite sides of the fuse are able to move M away from each other, which displaces the bottom outer corner 1310, extending further away from the body 1306. Bottom outer corner 1310 is then configured to contact the side wall of the window jamb and reduce rotational movement of the jamb mount. Additionally, the side pillar mounting piece 1300 may include the bump 1312 described above. In another example, the jamb mount 1300 can be formed without the presence of material (e.g., a slit or gap in the body of the jamb mount) at the location of the mechanical fuse capable of effecting the motions described herein.

Fig. 17A is a perspective view of another inverted constant force window counterbalance system 1400 that may be used with the hung window frame assembly 10 (shown in fig. 1A). Fig. 17B is an internal view of window balancing system 1400. Referring to fig. 17A and 17B concurrently, window balancing system 1400 is shown in a transport configuration (e.g., a mounting bracket removably connected to a main housing assembly) and includes a main housing assembly 1402, a mounting bracket 1404, and a slipper assembly 1406. The main housing assembly 1402 houses a first coil spring 1408 and a second coil spring 1410 connected to the mounting bracket 1404. As described above in fig. 12A-12D, the top end 1412 of the main housing assembly 1402 is removably connected to the mounting bracket 1404. The bottom end 1414 of the main housing assembly 1402 is removably connected to the slipper assembly 1406. The slipper assembly 1406 includes a locking system 1416 that enables the window balancing system 1400 to be secured within the window jamb during operation as described herein. In some examples, the locking system 1416 can include a cam 1417 with a closed keyhole 1418.

The main housing assembly 1402 may include an upper internal cavity 1420 housing the coil spring 1410 and a lower internal cavity 1422 housing the coil spring 1408. The lumens 1420, 1422 are each defined by an upper annular surface 1424 and a lower annular surface 1426. The upper annular surface 1424 can include a plurality of radially extending recesses 1428 that help reduce the surface friction of the upper annular surface 1424 as the coil spring rotates therein. The lower annular surface 1426 may include a debris collection portion 1430 that helps remove dirt and debris that may accumulate within the cavity. In this example, the main housing assembly 1402 is configured to house two coil springs 1408, 1410 in separate cavities. In other examples, the upper and lower cavities may be combined into one larger cavity that houses two coil springs.

Fig. 17C is a perspective view of the window balancing system 1400 shown in fig. 17A and 17B in an alternative configuration 1400B. In this configuration, the main housing assembly 1402 is connected to the secondary housing assembly 1432. Similar to the alternative configuration of the window balancing system 20 shown in fig. 1E-1G, the window balancing system 1400 may be connected to one or more secondary housing components such that the spring rate and the rated balance weight of the window balancing system may be increased as required or desired to enable operation in larger/heavier sash sizes. Additionally, in this example, the cam 1417 may have an open keyhole 1418 to receive a pivot rod 1434 as described herein.

Fig. 18A is a partial perspective view of a portion of a main housing assembly 1500 for use with the window balancing system 1000 (shown in fig. 10). Fig. 18B is a plan view of the main housing assembly 1500 mounted in the window jamb 1514. Referring to fig. 18A and 18B concurrently, the main housing assembly 1500 is substantially similar to the main housing assembly 1004 (shown in fig. 10), and thus certain components are described above and not further described. However, in this example, the housing members 1502, 1504 forming the main housing assembly 1500 each include an outer wall 1506 having one or more ribs 1508 extending therefrom.

In this example, the outer wall 1506 includes two ribs 1508 that generally extend from a lower portion 1510 of the housing members 1502, 1504 to an upper portion 1512 of the housing members 1502, 1504. In one example, the ribs 1508 are spaced about 0.5 inches apart, and the ribs themselves are about 0.025 inches wide and 0.006 inches high. The ribs 1508 have a substantially dome-shaped profile. In other examples, the ribs 1508 may have any other size, spacing, and/or shape as needed or desired. For example, instead of extending substantially the entire length of the outer wall 1506 from the lower portion 1510 to the upper portion 1512, the ribs 1508 may be segmented into spaced apart portions along the entire length of the outer wall 1506. Additionally or alternatively, the ribs 1508 may be included on a secondary housing assembly (e.g., secondary housing assemblies 300, 1086, and 1432 (shown in fig. 3A, 14, and 17C, respectively)) or other primary housing assemblies described herein (e.g., primary housing assemblies 100 and 1402 (shown in fig. 2A and 17A, respectively)). In another example, the ribs 1508 may have a rectangular, square, or triangular profile.

In operation, the main housing assembly 1500 substantially encloses the coil spring disposed therein, thereby preventing dirt and debris present within the window jamb 1514 from accumulating on the coil spring. However, due to the closed enclosure system, the outer wall 1506 has a large surface that directly abuts and slides over the window jamb 1514, and dirt and debris may adhere to the outer wall 1506. This accumulation of dirt and debris increases the frictional resistance between the window balancing system and the window jamb 1514 and reduces the performance of the window balancing system. By including the ribs 1508 on the outer wall 1506, the surface area of the main housing assembly 1500 that slides on the window jamb 1514 is reduced, thereby improving the performance of the window balancing system. In addition, the ribs 1508 create gaps 1516 between the outer wall 1506 and the window jamb 1514 to allow dirt and debris to fall therefrom and not adhere to the outer wall 1506.

In this example, because the housing members 1502, 1504 each have the same configuration, the main housing assembly 1500 will have ribs 1508 on both sides (e.g., the side adjacent to the rear wall 1518 of the window jamb 1514 and the side adjacent to the front wall 1520 of the window jamb 1514) when assembled together. As such, the ribs 1508 are located on the outer wall 1506 such that the ribs 1508 are located between the front walls 1520 of the window side pillars 1514 and do not extend beyond the thickness of the front walls 1520 when installed in the window side pillars 1514. In other examples, ribs 1508 may be positioned on outer wall 1506 such that ribs 1508 abut and slide along front wall 1520 and rear wall 1518 and ensure that a gap is also formed between main housing assembly 1500 and front wall 1520.

In addition, the ribs 1508 also add strength to the thin outer wall 1506 (e.g., the portion of the housing defining the interior cavity that houses the coil spring). For example, the outer wall 1506 may support an increased weight when multiple window balancing systems are stacked on top of each other during transport. In addition, the ribs 1508 facilitate manufacture of the housing members 1502, 1504. Because outer wall 1506 is relatively thin, material flow along outer wall 1506 is increased by adding ribs 1508 when molding housing members 1502, 1504.

Fig. 19A is a perspective view of a baffle 1600 for use with window balancing system 1000. Fig. 19B is an exploded perspective view of baffle 1600. Fig. 19C is a cross-sectional view of a portion of window balancing system 100 depicting baffle 1600. Certain components of the window balancing system 1000 are described above with reference to fig. 10 and need not be described further. Referring also to fig. 19A-19C, baffle 1600 is removably connected to top end 1014 of window counterbalance system 1000. While baffle 1600 is shown and described with respect to window balancing system 1000, baffle 1600 may be used with any other window balancing system described herein, such as window balancing system 20 (shown in fig. 1B).

During operation of the window balancing system 1000, after the mounting bracket 1006 is detached from the main housing assembly 1004, the top end 1014 of the main housing assembly 1004 is exposed to dirt and debris within the window jamb. As such, the open channels 1038 on the top end 1014 can accumulate dirt and debris. To prevent such accumulation, the baffle 1600 may be removably connected to the top end 1014 of the main housing assembly 1004 after detaching the mounting bracket 1006. Baffle 1600 includes clamping member 1602 and scraping member 1604.

Clamping member 1602 includes a plate base 1606 having a bottom elongate element 1608 extending therefrom. The bottom extension element 1608 is shaped and sized to engage the top receiving element 1030 of the main housing assembly 1004. The bottom extension element 1608 may include two bottom extension arms 1610, 1612. The bottom extension arms 1610, 1612 may be separated by a gap 1614 extending therebetween. The bottom extension arms 1610, 1612 each include a toe portion 1616 adjacent the straight portion 1618. In this example, toe portion 1616 of first elongate arm 1610 is opposite straight portion 1618 of second elongate arm 1612. This enables the bottom elongated element 1608 to correspond to the shape of the channel 1038 shown in fig. 11A and 11B, with the protrusion 1050 opposing and opposite the side surface 1042.

Similar to the detents on mounting bracket 1006 described above with reference to fig. 12B, toe portion 1616 has detents extending therefrom. The claw may be formed as a toe 1620 having two inclined surfaces 1622, 1624. In this example, the top inclined surface 1622 may correspond to the protrusion inclined surface 1052 of the protrusion 1050. In operation, toe 1620 frictionally engages protrusion 1050 to secure baffle 1600 to the main housing assembly. The straight portion 1618 may be sized and shaped to be positioned adjacent to the straight side surface 1042. The tip of the straight portion 1618 may also include an inclined surface 1626 to accommodate a bottom inclined surface 1049 of the channel 1038. In operation, the bottom extension arms 1610, 1612 may be resilient to deflect at least partially into the channel 1038 of the main housing assembly 1004 and engage the protrusion 1050.

The wiper 1604 is substantially rectangular in shape and includes an aperture 1628 defined therein. The aperture 1628 enables a portion of the clamp 1602 (e.g., the bottom extension element 1608) to extend through the wiper 1604 and connect to the main housing assembly 1004. This sandwiches the wiper 1604 between the base 1606 and the main housing assembly 1004. The wipers 1604 are sized to protrude into the window jamb when installed so that dirt and debris can be removed from the window jamb surface during sliding movement of the window balancing system. The wiper 1604 is also positioned inboard of the free end 1012 of the coil spring 1010. One or more channels 1630 may be defined on one or more edge surfaces of the wiper 1604 to help facilitate wiping of window jamb surfaces and to guide dirt and debris away from the main housing assembly 1004.

Fig. 20A is a perspective view of another jamb mount 1700 for use with the window balancing system 1000 (shown in fig. 10). Fig. 20B is a plan view of the side pillar mount 1700. Referring to both fig. 20A and 20B, certain components are described above in other examples and are therefore not further described. The side post mount 1700 is substantially similar to the side post mount 1022 described with reference to fig. 10 and is configured to engage the coil spring mount 1024. However, in this example, the body 1702 of the side post mount 1700 terminates at a side 1704 that abuts a collar 1706 surrounding the mounting aperture 1708 and opposite the side extension arms 1710, 1712. Collars 1706 are also provided on opposing surfaces of the side pillar mounts 1700. By reducing the length L of the body 1702, the side 1704 is positioned away from the side wall 1714 of the window jamb 1716 when installed. As such, the jamb mount 1700 can fit a jamb cover 1718, which can be positioned within the window jamb 1716 and cover the jamb mount 1700 for aesthetic or other purposes.

Fig. 21 illustrates an exemplary method 1800 of installing a window balancing system (e.g., the window balancing system depicted herein) in a window jamb. In this example, the window balancing system may include a mounting bracket coupled to a carrier assembly having a coil spring disposed therein. The window balancing system is positioned within the window jamb such that the mounting bracket is positioned above the carrier assembly (operation 1802). Once inside the window jamb, the mounting bracket is secured to the window jamb such that at least a portion of the mounting bracket slides relative to the free end of the coil spring and toward the window jamb (operation 1804). Substantially simultaneously with the securing operation, the mounting bracket is detached from the carrier assembly such that the carrier assembly is configured to move within the window jamb (operation 1806). The load bearing assembly may then receive at least a portion of the pivot rod connected to the sash (operation 1808).

In some examples, the jamb mount slides relative to the coil spring mount from the first position to the second position when the mounting bracket is secured (operation 1810), and the mounting bracket toe disengages from the carriage assembly projection when the mounting bracket is detached from the carriage assembly (operation 1812). In other examples, the bearing assembly includes a slipper assembly that receives a pivot rod (operation 1814), and more specifically, a rotating cam of the slipper assembly may receive the pivot rod (operation 1816).

Fig. 22 illustrates an exemplary method 1900 of assembling a slipper assembly (e.g., the slipper assembly depicted herein) for an inverted constant force window balancing system. The slipper assembly may include a rotating cam, a housing, and at least one brake shoe. The rotating cam is axially aligned with the housing (operation 1902) and the rotating cam slides through the top opening of the housing and into the cam opening of the housing (operation 1904). In some examples, sliding of the rotating cam through the top opening deflects each leg of the housing (operation 1906). In other examples, at least one brake pad is coupled to the brake pad receiving portion of the housing such that the at least one brake pad is configured to be engaged by an outer cam surface of the rotating cam (operation 1908).

The materials used in the joining system described herein may be those materials typically used in the manufacture of windows and window components. The material selection for most components may be based on the proposed use of the window. Suitable materials may be selected for sash retention systems used on particularly heavy window panels as well as windows subject to particular environmental conditions (e.g., moisture, corrosive atmospheres, etc.). Aluminum, steel, stainless steel, zinc or composite materials (e.g., for the coil spring mount body to prevent separation from the coil spring) may be used. A plastic that is bendable and/or mouldable may be particularly advantageous. For example, the housing and/or mounting bracket may be integrally formed with the engaging member and/or receiving member. In other examples, however, the engaging member and/or receiving member may be attached to the housing and/or mounting bracket as an accessory to the window balancing system.

Any number of the features of the different examples described herein may be combined into a single example, and alternate examples having fewer than or more than all of the features described herein are possible. It is to be understood that the terminology employed herein is for the purpose of describing particular examples only and is not intended to be limiting. It must be noted that, as used in this specification, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

While there have been described herein what are considered to be illustrative and preferred examples of the present technology, other variations of the present technology will become apparent to those skilled in the art in light of the teachings herein. The particular fabrication methods and geometries disclosed herein are exemplary in nature and should not be considered as limiting. It is therefore intended to cover in the appended claims all such modifications as fall within the spirit and scope of the technology. Accordingly, what is desired to be secured by letters patent is the technology defined and differentiated in the following claims, and all equivalents.