AU2007202762B2 - Interconnection of a mullion with a window frame or door frame - Google Patents

Abstract

A method is provided for interconnecting a mullion (23) to a head (1), sill (3), or transom (5) of a 5 door or window frame. The mullion (23) and the frame are of extruded or roll formed frame material. An end of the mullion (23) is shaped to fit relative to the head (1), sill (3) or transom (5) so an outermost weatherside exposed face (33) will appear as a finished joint 10 therewith. One or more free flanges (41) of the mullion (23) that extend transversely inwardly of the outermost weatherside exposed face (33) are positioned to align with at least an outer laterally extending flange (19) of the head (1), sill (3), or transom (5). One or more slots 15 (43) are provided in the laterally extending flange (19) and one or more of the free flanges (41) are inserted into a respective one of the slots (43). This positions the mullion (23). A part (45) of the mullion is then deformed to hold the mullion (23) located relative to the head (1), 20 sill (3), or transom (5). A door frame or window with an interconnected mullion (23) is also provided. H:\Priyanka\Keep\speci\P61731 - CAP Filing doc 14/06/07

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Standard Patent Applicantss: Aluminium Extrusion and Distribution Pty Limited Invention Title: INTERCONNECTION OF A MULLION WITH A WINDOW FRAME OR DOOR FRAME The following statement is a full description of this invention, including the best method for performing it known to me/us: - 2 INTERCONNECTION OF A MULLION WITH A WINDOW FRAME OR DOOR FRAME 5 Field of the Invention This invention relates to interconnection of a mullion to a window frame or a door frame. 10 Background Art Hitherto, mullions have been interconnected to a window or door frame of extruded or roll formed metal by connecting either with the head and sill, or with the head 15 and a transom, or with the sill, and the transom. The mullion is of extruded or roll formed metal and it is a requirement for aesthetic reasons that the mullion has a finished joint appearance at the interconnection with the head, sill or transom. In other words, from the outermost 20 weatherside exposed face of the window or door frame a finished joint with the mullion should appear neat. Hitherto, it has been common to pop rivet or screw fix the mullion to transversely extending flanges of 25 the respective head, sill or transom. Such fixing involves a time consuming manual operation. Once fixed, the pop rivets or the heads of screws are clearly visible from the outermost weatherside exposed face of the frame and this tends to provide for an unsightly aesthetic 30 appearance. Statement of the Invention The present invention has been devised to attempt 35 to provide alternative fixing which in some cases may result in less labour content and which will provide for an improved aesthetic appearance. H:\Priyanka\Keep\spe:i\P61231 - CAP Filing.doc 14/06/07 - 3 According to a first broad aspect of the invention there is provided a method of interconnecting one end of a mullion to a window or door frame 5 (hereinafter called window frame), said mullion and said window frame being of extruded or roll formed frame material, said method comprising shaping the top or bottom end of the mullion to fit relative to a head, sill or a transom of said window frame so an outermost weatherside 10 exposed face of the mullion will appear as a finished joint therewith and so there is one or more free flanges that extend transversely inwardly of the outermost weatherside face of the mullion at the one end of the mullion, said one or more free flanges being positioned to 15 align with at least an outer laterally extending flange of the respective head, sill or transom, providing a corresponding one or more slots in the outer laterally extending flange of the respective head, sill, or transom, 20 inserting the one or more free flanges of the mullion in the corresponding one or more slots in the outer laterally extending flange of the respective one of the head, sill, or transom to position the mullion, and then deforming a part of the mullion to hold the mullion 25 located relative to the head sill or transom. In one example the deforming of the part of the mullion is a deforming of a further flange attached to the one or more free flanges to retain the one end of the 30 mullion fixed. Brief Description of the Drawings In order that the invention can be more clearly 35 ascertained, examples of preferred embodiments will now be described with reference to the accompanying drawings wherein: H:\PI iyanka\ Kep\speci\P6I11 - CAP Fil)ing doc 14/06,07 - 4 Figure la is a perspective view from an outermost weatherside face of the window frame or door frame (hereinafter called 'window frame') and showing a close-up 5 view an interconnection of the mullion with the head, sill, and transom, Figure lb is a view similar to that shown in Figure la but from the innermost non-weatherside face of 10 the frame, Figure 2 is an end elevation view showing interconnection of a mullion at a sill, 15 Figure 3 is a close-up perspective view from the innermost non-weatherside face of the mullion showing shaping at one end, and taken from the right hand side of a mullion, 20 Figure 4 is a view similar to that in Figure 3 but taken from the left hand side of the mullion, Figure 5 is a view similar to that in Figure 3 showing the way in which a part of the mullion is deformed 25 to hold the mullion fixed relative to a head, sill, or transom, and taken from the right hand side of the mullion, Figure 6 is a view similar to that in Figure 5, 30 but taken from the left hand side of the mullion, Figure 7 is an exploded perspective view showing how a mullion locates within a transom, 35 Figure 8 is a view similar to that in Figure 7 showing the mullion fitted to the transom, H:\Priyanka\Keep\speci\P61731 - CAP Filing doc 14/06/02 -5 Figure 9a and Figure 9b are views similar to that shown in Figures la and lb but of a further example, Figure 10 is an exploded perspective view showing 5 how the mullion of Figures 9a and 9b fits relative to a head, Figure 11 is a side elevational view showing the same fitting process shown in Figure 10, 10 Figure 12 is a view showing the mullion fitted to the head, Figure 13 is a perspective view taken from an 15 innermost non-weatherside exposed face showing the end profile of a mullion and taken from a left hand side of the mullion, Figure 14 is a view similar to that shown in 20 Figure 13 but taken from the right hand side of the mullion, and showing how parts of the mullion are deformed to hold the mullion fixed to a head, sill or transom, Figure 15 is an underneath assembled perspective 25 view showing the mullion fixed relative to the head, Figure 16 is a bottom view of the connection shown in Figure 15, and 30 Figure 17 is a side elevational view showing connection of the mullion at a sill. Detailed Description of Examples of Preferred Embodiments 35 Referring firstly to the example in Figures 1 8, there is shown detail of connection of a mullion to a 1-\Priyanka\Keep\speci\P61731 - CAP Filing.doc 14/06/07 -6 head, a sill and a transom of a window frame or door frame (hereinafter referred to as window frame). The jamb connections have not been shown as these connections are standard. The window frame includes a head 1, a sill 3, 5 and a transom 5, all extrusion formed from metal such as aluminium. The particular cross sectional profile of the head 1, sill 3 and transom 5 may be formed in alternative ways such as by roll forming. In the case of roll forming, the transverse cross sectional profile will be 10 slightly different owing to the roll forming process, but the concepts of the invention apply equally as well and are to be included within the scope of the invention. Each of the head 1 and the sill 3 are provided with respective glazing channels 7 and 9 defined by laterally 15 extending flanges 11 and 13. The transom 5 is provided with two glazing channels 15 and 17 formed by laterally extending flanges 19 and 21. Each of the glazing channels 7, 9, 15 and 17 are vertically aligned with one another and have identical transverse cross sectional widths. The 20 channels 7, 9 and 15 have similar depths whereas channel 17 has a similar depth but the uppermost part of the channel 17 is angularly inclined downwardly. Figure la shows a view from the outermost 25 weatherside exposed face of the frame, whereas Figure lb shows a view from the innermost non-weatherside exposed face of the frame. Accordingly, when viewing Figure la, it can be seen that a mullion 23, in the form of an upper mullion 23 and a lower mullion 23 extends between the head 30 1 and the transom 5, and the transom 5 and the sill 3. The cross sectional profiles of the upper mullion 23 and the lower mullion 23 are identical, except that the upper mullion has a flange extension 24 to locate with a sliding sash window frame that can slide laterally from side to 35 side within the window frame, in a known manner. The sliding sash traverses in a sash channel 26. The top and bottom ends of each of the upper and lower mullion 23 are H:\Pryanka\Keep\SpeCi\P61231 CAP Filing-doc 14/06/07 -7 shaped to fit relative to the respective head 1, sill 3 and transom 5 so an outermost weatherside exposed face will appear as a finished joint therewith. Figure la clearly shows the finished joint arrangement. It is noted 5 that the head 1 has a lower shallow step 25, the sill 3 has an upper shallow step 27, and the transom 5 has a upper shallow step 29 and a lower shallow step 31. An outermost weatherside face 33 of the mullions 23 is arranged to align coplanar with a corresponding outermost 10 weather face 35, 37, or 39 of the head 1, sill 3, and transom 5. Figure la shows that for the transom 5 there are two outermost weather faces 35, one being at the lower part of the transom, and being an extension of the downwardly inclined top of the glazing channel 17 adjacent 15 the lower glazing channel 17. The other is adjacent the upper glazing channel 15. The outermost weather face 35 of the sill 3 is a bead edge opposite glazing channel 9. The outermost weather face of the head 1, is opposite glazing channel 7. In each case, the outermost weather 20 face 33 of the mullion 23 fits flush with the corresponding outermost weather face 35 on the head 1, sill 3 and transom 5. Each end of the mullion 23 is therefore 25 appropriately shaped to enable this finished joint appearance to occur, and to provide one or more free flanges 41 that extend transversely inwardly of the outermost weatherside face of the mullion 23. The free flanges 41 are not clearly shown in Figures la or Figure 30 lb but are shown in other figures such as in Figures 3 6. The free flanges 41 are arranged to align with an outer laterally extending flange 11, 13, 19 or 21, of the glazing channels 7, 9, 15 or 17. Figure 7 clearly shows that in this example there are three of the one or more 35 slots 43 in the laterally extending flange 19 of the transom 5. In this case, the one or more free flanges 41 of the mullion 23 locate in a respective corresponding one H:\Priyanka\Keep\speci\P61231 - CAP Filing.doc 14/06/02 - 8 of the slots 43 and laterally align the mullion 23 relative to the transom 5. Similar slots 43 are provided in the laterally extending flanges of the head 1 and the sill 3, and locate the opposite ends of the mullion 23 in 5 a similar manner. Thus, when the one or more free flanges 41 are inserted within the corresponding one or more slots 43, a part of the mullion 5 may be deformed to retain one end of the mullion 23 fixed to the respective head 1, sill 3 or transom 5. In the example shown, the one or more 10 free flanges 41 have a further flange 45 extending therefrom. In this example, it is the further flange 45 as the part of the mullion that is deformed to retain the respective ends of the mullion 23 fixed. It should be appreciated however, that other parts could be deformed 15 instead, such as one or more of the free flanges 41 by displacing a part of the free flange 41 from being co planar with the face of the free flange 41, to thereby locate behind a laterally extending flange 11, 13, 19, or 23. In the case of the example shown, the free flange 45 20 is displaced and deformed by bending to locate under a shoulder 47 forming part of the glazing channels 7, 9, 15, and 17. This, in turn, locks the mullion 23 against up and down movement relative to the head 1, sill 3 or transom 5. This is clearly shown in Figure 8. 25 Figures 3 - 7 clearly show that the further flange 45 is formed as a tab by providing a notch 49 in the further flange 45 near the end of the mullion 23. Figure 7 clearly shows that the three slots 43 are 30 arranged to receive respective free flanges 41. Figures 3 - 6 clearly show a slot 51 machined in the free flange 41 at the position where the free flange 41 joins the outermost weather face 33. The slot 51 is provided to receive a part of the laterally extending flanges 19, 21. 35 The mullion 23 is therefore fitted to the transom 5 by the free flange 41 locating with the central slot 43 and then being slid vertically downward to interlock the central H:\Priyanka\Keep\speci\P61:31 - CAP Filing doc 14/06/07 - 9 slot 43 with slot 51. As the mullion 23 is slid downwardly within the slots 43, the central slot 43 engages and overlaps with the slot 51. The depth of slots 43 and 51 in the longitudinal direction of the mullion 5 5 are equal to the depth of the glazing channel, and equal to half the depth of vertical movement of the mullion as it moves to fully locate with the transom 5, head 1, or sill 3. The end of slot 51 coincides in depth with the end of the two outer flanges 41 which are shown set back 10 from the extreme end of the mullion. The two outermost free flanges 41 of the mullion 23 locate in the outermost slots 43. Figures 3 - 6 clearly show that the innermost 15 non-weatherside exposed face 53 of the mullion 23 is machined with a step so that the free end of the innermost non-weatherside exposed face 53 at the end of the mullion 23 is short of the extreme end of the mullion 23. Figures 3 - 6 also show that the outermost weatherside face 33 of 20 the mullion 23 has two side wings 55. The side wings 55 are machined to have the same distance of spacing from the extreme end of the mullion 23 as that of the end of the innermost non-weatherside exposed face 53. Thus, when the mullion 23 is fitted relative to the head 1, sill 3 or 25 transom 5, the ends of the side wings 55 and the innermost non-weatherside exposed face 53 align directly above the respective side walls of the glazing channels. Figure 8 clearly shows the arrangement. It should be noted that the wings 55 are formed as a transverse step in the 30 outermost weather face 33 of the mullion 23, and align with faces of a corresponding transverse step in the outermost weather face of the head 1, sill 3, or transom 5. 35 Referring now to the example shown in Figures 9a - 16, it should be appreciated that the concepts of are very similar to the previous example and the features of H:\Priyanka\KeC \speci\P6123! - CAP Filing.doc 14/06/07 - 10 the head 1, sash 3, transom 5, and mullion 23 are substantially identical and have similar cross section profiles. In this example, the ends of the mullion are shaped slightly differently such that the upper and lower 5 mullions 23 can swing into position rather than be vertically slid into position for fixing. Thus, the examples shown in Figures 9a - 16 lends itself to retro fitting to an existing window frame. Because the transverse cross sections of the head 1, sill 3, transom 10 5, and mullion 23 have the same transverse cross sectional profile as previously discussed, like reference numerals have been provided and the related description omitted. In this example, the part of the mullion 23 that is deformed is the one or more free flanges 41. The further 15 flange 45 does not have a tab 45 as in the previous example which is deformed. In other words, in this example, a tab 45 is not provided on the mullion 23. Thus, in this example, there are three free flanges 41 (see Figures 10, 13, and 14) and parts of the outermost 20 free flanges 41 are deformed to interlock the mullion 23 relative to the head 1, sill 3 and transom 5. The parts that are deformed have been identified by numeral 57. It can be seen that the parts 57 that are deformed are formed in the one or more free flanges 41 by cutting slots 59 25 near the ends of the mullion 23 and into the one or more free flanges 41. It can also be seen that the central free flange 41 has a cut-out 61 to enable the central free flange 41 to clear the internal shoulder 47 within the glazing channel. This is clearly shown in Figure 11, and 30 in Figure 12. Figure 17 shows the interconnection of the mullion 23 at the sill 3. Because the general transverse cross sectional profile of the glazing channel is the same 35 as that in the corresponding glazing channels of the transom and/or head, the shaping at that end of the mullion 23 that connects with the sill is the same as that H:\Priyanka\Keep\spec1\P61?31 - CAP Filinqdoc 14/06/07 - 11 shown and explained in relation to Figures 9a - 16 for the ends that connect with the head . Whilst the head 1, sill 3, transom 5, and mullion 5 23 have been described as being of extruded or roll formed metal, it is envisaged that if other suitable materials are used such as plastics material instead of metal, then the inventive concepts equally apply, and that the use of plastics material for these components is not outside the 10 scope of the invention. Whilst bending of parts of the mullion have been disclosed as a way of fixing the mullion to the head 1, sill 3 or transom 5, other forms of deformation such as 15 crimping, clinching or otherwise deforming is to be included within the scope of the invention. These and other modifications may be made without departing from the ambit of the invention the nature of 20 which is to be determined from the foregoing description. It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part 25 of the common general knowledge in the art, in Australia or any other country. In the claims which follow and in the preceding description, except where the context requires otherwise 30 due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in 35 various embodiments of the invention. Hi\Priyanka\Yeep\speci\P61731 - CAP Filing doc 14/06/07

Claims (8)

1. A method of interconnecting one end of a mullion to a window or door frame (hereinafter called window 5 frame), said mullion and said window frame being of extruded or roll formed frame material, said method comprising shaping the top or bottom end of the mullion to fit relative to a head, sill or a transom of said window frame so an outermost weatherside exposed face of the 10 mullion will appear as a finished joint therewith and so there is one or more free flanges that extend transversely inwardly of the outermost weatherside face of the mullion at the one end of the mullion, said one or more free flanges being positioned to align with at least an outer 15 laterally extending flange of the respective head, sill or transom, providing a corresponding one or more slots in the outer laterally extending flange of the respective head, sill, or transom, 20 inserting the one or more free flanges of the mullion in the corresponding one or more slots in the outer laterally extending flange of the respective one of the head, sill, or transom to position the mullion, and then deforming a part of the mullion to hold the mullion 25 located relative to the head sill or transom.

2. A method as claimed in claim 1 wherein the deforming of the part of the mullion is a deforming of the one or more free flanges or a further flange attached to 30 the one or more free flanges to retain the one end of the mullion fixed.

3. A method as claimed in claim 1 or claim 2, wherein both a top and a bottom ends of the mullion are 35 fixed to the window frame by shaping both the top and bottom ends of the mullion so the outermost weatherside exposed face of the mullion will appear as a finished H:\Priyanka\Keep\speci\P61731 - CAP Filinq-doc 14/06/07 - 13 joint with any two of the head, sill or transom, and so there is one or more free flanges that extend transversely inwardly of the outermost weatherside face at the top and at the bottom of the mullion, and so the free flanges are 5 positioned to align with the respective outer laterally extending flanges of any corresponding two of the head, sill or transom, and providing a corresponding one or more slots in each laterally extending flange of said corresponding 10 any two of the head, sill or transom, inserting the one or more flanges at both ends of the mullion into those corresponding slots of the corresponding two of the head, sill, or transom, and then deforming the one or more free flanges at 15 the top and at the bottom of the mullion to retain both ends of the mullion fixed.

4. A method as claimed in any one of the preceding claims, wherein the laterally extending flange is a wall 20 of a laterally, extending channel in each of the head sill or transom, and wherein the laterally extending channels of the head, sill or transom are each of the same cross sectional profile which is open in a direction facing the longitudinal length of the mullion. 25

5. A method as claimed in any one of the preceding claims, wherein the transom has two vertically aligned laterally extending channels, one channel being on an upper side region of the transom and the other being on 30 the underside region of the transom.

6. A method as claimed in any one of the preceding claims, wherein there are three free flanges that extend laterally inwardly of the outermost weatherside face of 35 the mullion of said one end and wherein there are three slots provided on the laterally extending flange of the respective head, sill or transom to receive respective H:\Priyanka\Keep\speci\P61731 - CAP Filing doc 14/06/02 - 14 ones of the three free flanges of the mullion, and wherein the outermost two of those free flanges are deformed to retain the one end of the mullion fixed. 5

7. A window frame having a mullion interconnected by the method of any one of claims 1 to 6.

8. A method of interconnecting one end of a mullion to a window or door frame substantially as herein described 10 with reference to the accompanying drawings. 4686082_1 (GHMatters) P61731.AU.1 12/09/13