AU2007234566B2 - Interconnection of a mullion with a window frame or door frame - Google Patents

Abstract

A method of interconnecting one end of a mullion (23) to a window frame, such as a head (1), sill (3) or 5 transom (5) is provided. The end of the mullion (23) is shaped to fit with the head (1), sill (3), or mullion (5) so an outermost weatherside exposed face (33) of the mullion (23) will appear as a finished joint therewith. An aperture (41) is provided in a generally horizontally 10 extending part of the head (1), sill (3) or mullion (5). A peg (45) is located with the aperture (41) so the peg (45) extends over a part of mullion (23). The peg (45) is then fixed in that located position to hold the mullion (23) located relative to the head (1), sill (3) or transom 15 (5). H:\Priyanka\Keep\speci\P61259 - MULLION JOINTING.doc 20/11/07

Description

- 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. Objects and 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\speci\P61259 - MULLION JOINTING.doc 20/11/07 -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 (hereinafter called window frame), said method comprising 5 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 mullion will appear as a finished joint therewith, providing an aperture in a generally horizontally extending part of the 10 respective head, sill or transom that is disposed inwardly of an exposed weatherside face thereof at a position corresponding to where the mullion is to be fixed, locating a peg within said aperture and so said peg extends over a part of said mullion and fixing said 15 peg in that located position to hold said mullion located relative to the head, sill or transom, wherein the peg has a fixing arm extending in a direction laterally outwardly from the longitudinal extent of the peg, and the fixing arm is located within a fixing aperture in a flange part 20 of the mullion, the flange part being inward of the exposed outer weather side face of the mullion. Preferably said peg is arranged to slide within a channel in said mullion during the location of said peg 25 with said aperture. Brief Description of the Drawings In order that the invention can be more clearly 30 ascertained, examples of preferred embodiments will now be described with reference to the accompanying drawings wherein: Figure la is a perspective view from an outermost 35 weatherside face of the window frame or door frame (hereinafter called "window frame") and showing a close-up view of interconnection of the mullion with the head, sill 4378257_1 (GHMatters) P61259.AU.1 4/06/13 - 3a and transom, Figure lb is a view similar to that shown in Figure la but from the innermost non-weatherside face of 4378257_1 (GHMatters) P61259.AU.1 4/06/13 -4 the frame, Figure 2 is a top perspective view showing interconnection of a mullion at a head, 5 Figure 3 is an exploded perspective view of the example shown in Figure 2 clearly showing the use of a peg for interconnection of the mullion with the head, 10 Figure 4 is a side elevational view, in exploded form, showing the arrangement in Figure 3, Figure 5 is a top perspective view of a mullion showing a peg for insertion within a channel therein, 15 Figure 6 is an assembled side elevational view showing a mullion and a head interconnected by a peg, Figure 7 is a side elevational view showing the 20 connection of an upper and lower mullion with a transom, Figure 8 is a side elevational view showing connection of a transom with a sill, 25 Figure 9 is a perspective view of a "partly folded" peg made from sheet metal, Figure 10 is a perspective view of the peg shown in Figure 9 but in a "fully folded" condition ready for 30 use, Figure Ila and Figure 1lb are views similar to those shown in Figures la and lb but of a further example, 35 Figure 12 is an exploded perspective view showing the way in which the mullion can interconnect with a head in the example of Figures 11a and 11b, H:\Priyanka\Keep\speci\P61259 - MULLION JOINTING.doc 20/11/07 - 5 Figure 13 is a perspective view from a non weatherside face of a mullion showing the profile at the end of the mullion, 5 Figure 14 is a top perspective view of the end of the mullion shown in Figure 13 but from the opposite side, Figure 15 is a perspective view showing placement 10 of a peg through a head and into a mullion, Figure 16 is a view similar to that shown in Figure 15 but with the peg in a fully inserted position, 15 Figure 17 is a side elevation showing the head and mullion interconnected with the peg, Figure 18 is a plan view of the example as shown in Figure 17, 20 Figure 19 is a an exploded perspective view showing interconnection of an upper mullion, and a lower mullion, with a two-part transom, 25 Figure 20 is a view similar to that in Figure 19 showing interconnection of pegs to connect the mullion with parts of the transom, Figure 21 is a view similar to that in Figure 20, 30 Figure 22 is a perspective view similar to that in Figure 21 but showing the two-part transom interconnected to form a single transom. 35 Detailed Description of the Preferred Embodiments Referring firstly to the example shown in Figures H:\Priyanka\Keep\speci\P61259 - MULLION JOINTING.doc 20/11/02 - 6 la to 10, there is shown detail of connection of a mullion to a 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 5 are standard. The window frame includes a head 1, a sill 3, and a transom 5, all formed from metal such as extruded aluminium. A 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 10 forming, the transverse cross sectional profile will be slightly different owing to the roll forming process, but the concepts of the invention apply equally as well, and are to included within the scope of the invention. Each of the head 1, and sill 3 are provided with respective 15 glazing channels 7 and 9 defined by laterally 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 20 identical transverse cross sectional widths. The channel 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 weatherside exposed face of the frame, 25 whereas Figure lb shows a view from the innermost non weatherside exposed face of the frame. Accordingly, in 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 1 and the transom 5, and the 30 transom 5 and the sill 3. The cross sectional profiles of the upper transom 23 and the lower transom 23 are identical, except that the upper transom has a flange extension 24 to locate with a sliding sash that slides laterally from side to side within the window frame, in a 35 known manner. The sliding sash traverses in a sash channel 26. H:\Priyanka\Keep\9peci\P61259 - MULLION JOINTING.doc 20/11/07 - 7 The top and bottom ends of each of the upper and lower mullions 23 are 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 5 therewith. Figure la clearly shows the finished joint arrangement. It is noted that the head 1 has a lower shallow step 25, the sill 3 has an upper shallow step 27, and transom 5 has an upper shallow step 29 and a lower shallow step 31. An outermost weatherside face 33 of the 10 mullion 23 is arranged to align coplanar with a corresponding outermost weather face 35, 37, 39, of the head 1, transom 5 and sill 3. Figure la shows that for the transom 5, there are two outermost weather faces 37, one being at the lower part of the transom, and being an 15 extension of the downwardly inclined top of the glazing channel 7 adjacent the lower glazing channel 17. The other is adjacent the upper glazing channel 15. The outermost weather face 35 of a sill 3 is a bead edge opposite glazing channel 9. The outermost weather face of 20 the head 1 is opposite glazing channel 7. In each case, the outermost weather face 33 of the mullion 23 is flush with the corresponding outermost weather face 35 on the head 1 outermost weather face 37 on the transom 5 and the outermost weather face 39 on the sill 3. 25 Each end of the mullion 23 is a appropriately shaped to enable this finished joint appearance to occur. Figure 3 shows that a slot 41 is provided in a 30 generally horizontally extending part 43 of the head 1. In this case, the slot 41 is an aperture which is disposed inwardly of an exposed outermost weatherside face 35 of the head 1. The slot 41 is provided at a position in the head 1 corresponding to where the mullion 23 is to be 35 fixed. In this example, the slot 41 is provided in the horizontally extending part 43 of the glazing channel 13 in the head 1. Similar slots 41 are provided in the H:\Priyanka\Keep\speci\P61259 - MULLION JOINTING.doc 20/11/07 - 8 horizontally extending parts of the glazing channels 15 and 17 of the transom 5 and the glazing channel 9 of the sill 3. Such slots 41 all provide apertures in the respective head 1, sill 3, and transom 5. 5 A peg 45 is located within the apertures formed by the slots 41 to hold the mullion 23 located relative to the head 1, sill 3 or transom 5. In each case a respective peg 45 is used. During the locating of the peg 10 45 within the aperture formed by the slot 41, a body part 47 of the peg 45 extends over a part 47 of the mullion 23. This is best shown in Figure 6 where it can be seen that the part 47 of the peg 45 overlies a laterally inwardly extending flange 49 of the mullion 23. In this example, 15 the peg is arranged to slide fit within a channel 51 in the mullion 23. This is best shown in Figure 5 where it can be seen that the channel 51 is defined by the laterally inwardly extending flange 49 and two further flanges 53. It is noted that one of the flanges 53 20 extends laterally inwardly from the outermost weather face of the mullion 23 and that the other of the flanges 53 extends from a inward non-weatherside face 55 of the mullion 23. The two flanges 53 extend inwardly towards each other in common planes but do not touch each other. 25 Figures 9 and 10 show one form of a peg 45. Here, the peg 5 is made from sheet metal and is generally elongate and has a body part 57 with a head 59. The head 59 has a width approximately equal but slightly less than 30 the width of the channel 51 such that the head 59 can slide longitudinally within the channel 51. The body part 57 is elongate such that it can penetrate into the aperture formed by the slot 41 in the head 1, sill 3, or transom 5. Figures 9 and 10 also clearly show that the 35 body part 57 has a fixing arm 61 which extends in a direction laterally outwardly from the longitudinal extent of the body part 57. In the example shown in Figures 9 H:\Priyanka\Keep\speci\P61259 - MULLION JOINTING.doc 20/11/07 -9 and 10, the peg 45 has two fixing arms 61. One fixing arm 61 extends to one side of the peg 45 whilst the other fixing arm extends to the opposite side of the peg 45. The fixing arms 61 are shown as being bent parts of the 5 sheet material from which the peg 45 is made. In each case, the fixing arms 61 are equal to half the width of the body part 45 and are laterally displaced along the width of the peg 45 by half that width. Because the peg is fabricated from sheet metal, as clearly shown by the 10 part folded arrangement in Figure 9 and the completely fold arrangement in Figure 10, the fixing arms 61 extend laterally outwardly from the peg 45 and are flexible such that there is some spring type action and resiliency provided. Thus, during fixing of the mullion 23 to the 15 head 1 or to the sill 3 or to the transom 5, the fixing arms 61 can be caused to deflect inwardly as the body part 45 penetrates the aperture formed by the slot 41. When the fixing arms move fully through the slot 41, they, inturn, spring outwardly by nature of the resilience and 20 spring action and extend over the horizontal extending part of the head 43, or the corresponding horizontally extending parts of the sill 3 or the transom 5. Thus, in order to fix the mullion 23 to the head 1 or sill 3 or the transom 5, pegs 45 are provided within the channels 51 and 25 slid to the extreme ends of the channels and through the respective apertures formed by the slots 41. When the fixing arms 61 spring outwardly, then the pegs 45 can be fixed to the mullion 23. 30 It should be noted that the spacing apart of the flanges 53 provides an opening 63 in the channel 51 that extends longitudinally along the length thereof. Accordingly, a person fixing the mullion 23 can manipulate the pegs 45 through the opening 63. When the fixing arms 35 61 have penetrated through the apertures formed by the slots 41, the peg 45 can be fixed relative to the mullion 23 by a pop rivet or screw or other fixing that passes H:\Priyanka\Keep\speci\P61259 - MULLION JOINTING.doc 20/11/07 - 10 through an aperture 65 in the head 59 of the peg 45. The aperture 65 has a width sufficient to allow the pop rivet or screw to pass therethrough without requiring further machining. In this way, the peg 45 can be fixed to the 5 mullion 23, which, in turn, then fixes the mullion 23 relative to the head 1, sill 3 or transom 5. Figures 4 - 6 clearly show that the ends of the mullion 23 are shaped to allow the finished joint 10 appearance of the interconnection of the mullion 23 with the head 1, sill 3, or transom 5. In this case, the laterally inwardly extending flange 49 and the flanges 53 are cut so that the free ends are in a plane that coincides with the cutting of the step 25, 27, 29 or 31 of 15 the head 1, sill 3, and transom 5. The step profile on the mullion 23 is of the same step profile as in the head 1, sill 3, or transom 5. Thus, when the mullion is fixed to the head 1, sill 3 or transom 5, it can be seen that an extension part 67 of the outermost weather face 33 is 20 coplanar with the outermost weather faces 35, 37 and 29 of the head 1, sill 3 and transom 5. This arrangement provides a neat joint appearance. It also aligns the step parts of the mullion directly above the corresponding step parts of the laterally extending flanges of the glazing 25 channels 7, 9, 15, 17. The above provides a neat joint appearance which does not require pop rivets and/or screws in the visible faces of the frame. 30 Reference will now be made to a second example by referring to Figures lla to 22. It should be appreciated that the concepts are of 35 a very similar in nature to the previous example and the features of the head 1, sill 3, transom 5 of the mullion are substantially identical and have generally similar H:\Piyanka\Keep\speci\P61259 - MULLION JOINTING.doc 20/11/07 - 11 cross section profiles, and with corresponding glazing channels 7, 9, 15, and 17. In this example, the ends of the mullion are shaped slightly differently. Because the transverse cross sections of the head 1, sill 3, transom 5 5 and mullion 23 previously discussed, like reference numerals have been provided and the related description omitted. In this example, the peg 45 is inserted substantially wholly through the aperture provided by the slot 41 through the generally horizontally extending part 10 of the head 1, or the corresponding parts of the sill 3, and the transom 5. In this arrangement, the pegs 45 then penetrate through the apertures formed by the slots 41 into the channel 51. 15 In this example, the peg 45 is shaped in a similar way from sheet metal and has similar fixing arms 61 at one end. Instead of having a head 59 as in the previous embodiment, the head 59 is formed by bending the end parts of the body part 57 generally at right angles so 20 that the end parts extend laterally outwardly from the body part 57. This is clearly shown in Figures 15 and 20. These figures also show that the width of the head 59 is of the same width as the width as the body part 57. Figure 12 shows that in addition to providing an aperture 25 by providing a slot 41 in the horizontally extending part of the head 1, sill 3, or transom 5, an opening 67 is machined in the front face of the laterally extending flange 11, or the corresponding flanges 13, 19 and 21 of the sill 3 or transom 5. Such openings 67 are provided to 30 enable the material of the flanges that define the channel 51 to pass therethrough. In other words, the width of the opening 67 is able to accommodate the thickness dimension defined across the outer faces of the laterally inwardly extending flange 49 and the corresponding faces of the 35 flanges 53. Thus, the mullion 23 can be fixed relative to the head 1, sill 3, or transom 5 by being slid inwardly through the opening 67, and so that the outermost H:\Priyanka\Keep\speci\P61259 - MULLION JOINTING.doc 20/11/07 - 12 weatherside faces are coplanar as in the previous example. The openings 67 are provided at positions along the length of the head 1, sill 3 and transom 5 that correspond to where the apertures formed by the slots 41 are provided. 5 Thus, when the mullions 23 are fitted and located relative to the head 1, sill 3 and transom 5, the mullions 23 can be fixed in position by passing the pegs 45, so that the body parts 57 penetrates the apertures, and so the body parts 57 then locate within the channels 51. In this 10 arrangement, the heads 59 overlie the generally horizontally extending part of the head 43 and the same generally horizontally extending parts of the sill 1 and transom 5. Figures 13 and 14 clearly show that an opening 69 is machined into each of the flanges 49 and 53 in 15 aligned relationship with each other. Such openings 69 are provided at each end of the mullions 23 and are placed at positions to coincide with the correct location of fixing arms 61 of the pegs 45. Thus, when the pegs 45 are fully inserted through the slots 41, the arms 61 can then 20 move outwardly through the openings 69 and lock the mullion 23 fixed relative to the head 1, sill 3 or transom 5. In this example, the transom 5 is a two part 25 transom that has an upper part 71 and a lower part 73 see Figures 20 - 22. In this case, the upper part 71 is arranged to snap lock fit with the lower part 73 to provide a combined transom 5. By providing the transom 5 as a two part transom, it enables easy fixing of the pegs 30 45 within the upper part 71 and the lower part 73. It should also be noted that the upper part 71 has the same profile as the sill 3. In this case, the sill 3 is a two part sill having an upper part 75 and a lower part 77 see Figures Ila and llb. The upper part 75 and the lower 35 part 77 are arranged to snap lock together. It should be appreciated that many modifications H:\Priyanka\Keep\speci\P61259 - MULLION JOINTING.doc 20/11/07 - 13 may be made without departing from the ambit of the invention. For example, whilst the head 1, sill 3, transom 5 and mullion 23 have been described as being of extruded or roll formed metal, it is possible they may be 5 made from other suitable materials. If other suitable materials are used, such as plastics material instead of metal, then the inventive concepts equally apply, and the use of plastics material for these components is not outside the scope of the invention. 10 Whilst the peg 45 has been formed from sheet metal, it could equally be formed from a solid piece of metal. Other materials could be used such as plastics material. The peg has been shown with fixing arms 61. 15 This is merely exemplary and fixing arms 61 could be dispensed with altogether. It should be appreciated that once the pegs 45 have penetrated through the apertures formed by the slots 41, and the pegs 45 fixed relative to either the head, sill or transom, or to the mullion, or 20 both, that the mullions 23 are then correspondingly fixed with the head 1, sill 3 and transom 5. Throughout the examples described, the interconnections at the head 1, sill 3 and transom 5 have 25 been shown identical for a given frame. Combinations of the fixing techniques described in both examples could be utilised in a single frame construction. These and other modifications are deemed within the scope of the invention the nature of which is to be determined from the foregoing 30 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 35 of the common general knowledge in the art, in Australia or any other country. H:\Priyanka\Keep\speci\P61259 - MULLION JOINTING.doc 20/11/07 - 14 In the claims which follow and in the preceding description, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or 5 "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 various embodiments of the invention. H:\Priyanka\Keep\Speci\P61259 - MULLION JOINTING.doc 20/11/07

Claims (10)

1. A method of interconnecting one end of a mullion to a window or door frame (hereinafter called window 5 frame), 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 mullion will appear as a finished joint therewith, providing an aperture in a generally 10 horizontally extending part of the respective head, sill or transom that is disposed inwardly of an exposed weatherside face thereof at a position corresponding to where the mullion is to be fixed, locating a peg within said aperture and so said 15 peg extends over a part of said mullion and fixing said peg in that located position to hold said mullion located relative to the head, sill or transom, wherein the peg has a fixing arm extending in a direction laterally outwardly from the longitudinal extent of the peg, and the fixing 20 arm is located within a fixing aperture in a flange part of the mullion, the flange part being inward of the exposed outer weather side face of the mullion.

2. A method as claimed in claim 1, wherein said peg 25 is arranged to slide within a channel in said mullion during the location of said peg with said aperture.

3. A method as claimed in any one of the preceding claims, wherein said peg has an elongate body part that 30 can penetrate into said aperture when said peg is located within said aperture, said body part having the fixing arm, the fixing arm extending in a direction laterally outwardly from the longitudinal extent of the body part. 35

4. A method as claimed in claim 3 when appended to claim 2, wherein said peg has two fixing arms extending in a direction laterally outwardly from the longitudinal 4378257_1 (GHMattera) P61259.AU.1 4/06/13 - 16 extent of the body part, one arm being on one side of the body part and the other arm being on the opposite side of the body part, and wherein there is a respective fixing aperture in said mullion on opposed walls of the mullion 5 that define a part of said channel.

5. A method as claimed in claim 1 or claim 2, wherein said peg has an elongate body part that can penetrate into said aperture when said peg is located 10 within said aperture, and wherein said peg has a fixing arm extending in a direction laterally outwardly from the longitudinal extent of the body part and positioning said fixing arm to extend across said aperture in said head, sill or transom and engage with 15 said horizontally extending part of the head, sill or transom, so that when said body part is fixed to said mullion, said mullion will be held fixed relative to the head, sill or transom. 20

6. A method as claimed in claim 5, wherein said body part has two fixing arms extending in a direction laterally outwardly from the longitudinal extent of the body part, one arm being on one side of the body part and the other arm being on the opposite side of the body part, 25 said one arm extending over a generally horizontally extending body part of the head sill or transom on one side of the aperture, and the other arm extending over a generally horizontally extending body part of the head, sill, or transom on the opposite side of the aperture. 30

7. A method as claimed in any one of the preceding claims, wherein said peg is a sheet metal peg and the fixing arm can flex relative to said body part, and wherein fixing involves flexing said fixing arm to locate 35 either within the fixing aperture in the mullion, or to extend across said aperture in said head, sill or transom. 4378257_1 (GHMatters) P61259.AU.1 4/06/13 - 17

8. A window frame having a mullion interconnected with a head, sill, or transom, by the method of any one of the preceding claims. 5

9. A method as claimed in any one of claims 1 to 7, and substantially as herein described with reference to the accompanying drawings.

10. A window frame as claimed in claim 8, and 10 substantially as herein described with reference to the accompanying drawings. H:\Priyanka\Keep\speci\P61259 - MULLION JOINTING doc 20/11/07