AU2009201583A1 - Improved modular building components and methods - Google Patents

Description

AUSTRALIA FB RICE & CO Patent and Trade Mark Attorneys Patents Act 1990 HARTMAN PACIFIC PTY LTD, MIBERLAN INDUSTRIAL CO LTD COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Improved modular building components and methods The following statement is a full description of this invention including the best method of performing it known to us:- 2 Cross-Reference to Related Applications The present application claims priority from Australian Provisional Patent Application No 2008902270 filed on 8 May 2008, the content of which is incorporated herein by reference. 5 Introduction to Invention This invention relates to the modular preparation of architectural fittings of the type embracing windows, doors and other similar items positioned into walls of houses, shops and other types of dwellings. 10 The provision of doors, windows and other architectural fittings traditionally relies on the preparation of specifications dedicated to specific requirements which are then constructed in accordance with the specific requirements and delivered to site for fitting during the building process. The provision of specific specifications and custom manufacturing of doors and windows, etc represents a highly costly laborious and in 15 particular, time consuming, component of many construction projects. In addition, large window units can be extremely heavy, particularly where double glazing is used, which renders the installation difficult and often requires the use of machinery or cranes to aid in installation. Whilst the concept of modularity has been around and practised in a wide range of construction and manufacturing industries, the provision of 20 a successful design system to provide true modularity for windows and doors has not currently emerged to satisfy and address the inefficiencies as previously described. One object of the invention is to provide an improved architectural fitting of the type including windows and doors. 25 Statement of Invention In a first aspect the invention provides an architectural fitting of the type including windows and doors, said fitting comprising a generally rectangular frame housing an infill panel of glass or the like, said frame being formed of at least two lengths of a channel shaped extrusion having a recessed base and two extending flanges 30 at the inner and outer edges thereof, wherein said recessed base includes one or a plurality of negative keyways for captively receiving an intermediate locking plate such that said locking plate can co-operate to lock two adjacent frames by slidable engagement so as to remain captive and fully contained within the two adjacent recessed bases. 35 The keyways are preferably formed inbound from said inner and outer edges so as to provide a fixing channel at or near said inner and outer edges for receiving 263313_1 3 fastening means to fix said channel lengths of a given frame together and make up said frame. The keyways are preferably obular shaped, but can adopt any interlocking shape. The intermediate locking plate preferably effects a snug sliding engagement of 5 adjacent frames such that the extending inner and outer flanges of adjacent frames are bought into abutment. The intermediate locking plate is preferably symmetrical in shape to allow engagement in any orientation and may include seals of rubber or the like. The frame may be infilled with a glass panel and preferably a double or triple 10 glassed panel. In another embodiment the infill panel may be a separate framed in-panel hinged or otherwise fitted to said frame. Detailed Description of Invention 15 The invention will now be described with reference to the accompanying figures and legend. Figure 1 shows a cross section view of the fitting. Figure 2 shows the joining portion of two adjacent frames. Figure 3 shows two frames joined vertically. 20 Figure 4 shows tow frames joined horizontally. Figures 5, 6 and 7 show the joining portion in a selection of embodiments. Referring to the figures, the invention will now be described with reference to one particularly preferred embodiment where the architectural fitting in question takes the form of a window. The architectural fitting of the invention could equally be 25 applied to a doorway or any other building element making up part of a dwelling or other construction. Referring firstly to Figures 1 and 2, the architectural fitting of the invention comprises a window having a generally rectangular frame 1 adapted for housing and infill panel 2, where the infill panel takes form of a window pane. The frame is formed 30 or made up of at least four lengths of extrusion where the side extrusions (or optionally top and bottom) extrusions form a channel shape 3 which in the embodiment shown in the Figures comprise four substantially equal lengths making up a square frame. Referring in particular to the channel shaped extrusions, the outside or external face 4 of the extrusion being that side or face directed to the outside of the completed 35 frame includes a recessed base 5 being defined by extending flanges 6 formed on the outer edge 7 and inner edge 8 of the channels. The extending flanges project out 263313_1 4 beyond the recessed base and are particularly adapted to mate with the corresponding frame joined thereto. The recessed base of the channel shaped extrusion includes one or a plurality of negative keyways 9 wherein the keyways are formed with a hollow recess and adapted for receipt of an interlocking intermediate locking plate 10. The 5 keyways are preferably positioned inboard of the extending flanges 6 of the channel so as to provide an area of fixing channel 11 between the outer keyways and the extended flanges 6. The prepared frames of adjacent architectural fittings are adapted for engagement by way of an intermediate locking plate 10 where the intermediate locking 10 plate has projecting tabs 12. The tabs 12 formed in the intermediate locking plate 10 are configured to engage by way of slidable interaction with the negative keyway 9 such that the co-operation of the negative keyway and projected tabs 12 ensure that the connecting tabs 12 are captive within the keyway 9 and serve to form a cooperative locking of the intermediate locking plate to the respective and adjacent channel shaped 15 extrusion components 3 of adjacent frames 1. The locking plate may be provided with a longitudinal seal 13 to ensure water and air tight seal between adjacent frames. In this manner, the intermediate locking plate provides for a slidable engagement of adjacent frames I where the recessed nature of the base 5 and sizing and dimensioning of the intermediate locking plate 10 ensures that the intermediate locking 20 plate is contained and held fully within the recessing provided by the butting recessed bases 5 where the adjacent frames I are drawn together such that the adjacent extending flanges 6 form a snug abutment and therein provide a seamless joining of the respective frames 1. The locking plate may also include seals 13 running the length of the plate to assist in providing a water and air seal across adjacent modules. 25 The provision of the keyways 9 inboard from the extending flanges 6 provide a fixing channel 11 which allows for the ready application of screws or other fastening means for joining together the vertical and horizontal lengths of channel shaped extrusion 3 which form the frame 1. The provision of the fixing channel 11 allows such fittings to be applied with no interference to the application and slidable 30 engagement of the intermediate locking plate once the frames I are assembled. Alternative shapes of the channel extrusion 3 and the locking plate are shown in Figures 5, 6 and 7, detailing a variety of embodiments, all exhibiting the features of the invention and providing various advantages. In addition the invention provides a range of finishing strip extrusions adapted 35 for engagement with the extrusions 3 making up the frame components so as to provide 263313_1 5 an edge or finish to an assembled collection of modular components making up a given door or window set. The modular architectural fitting of the invention provides the first time a truly modular system of doors and windows where the particular provision of the recess base 5 in the channel shaped extrusion allows for the assembly of an almost limitless number of frames without the loss of any modularity as the architectural fitting (window/door etc) of the invention does not require the use of packing or fitting systems that in any way interfere with the proportional sizing of the individual frames as built up in the current invention. In addition, the use of modular units of the invention allows very 10 large windows to be constructed and assembled on site without the use of cranes and handling equipment as each modular unit is readily handled without assistance. The interlocking channels of the architectural fitting as previously described, will, in most cases be sufficiently applied just to the side edges of the architectural fitting in question such that a plurality of windows or modular units can be assembled 15 side by side such that the side extruding members can be interlocked by way of the intermediate locking plate 10. In the situation where large assemblies of the modular units are required, in addition to the use of the keyed channel extrusion on the sides of the modular elements, the key channel extrusion can also be incorporated in the top and/or bottom extrusions 20 such that once a plurality of modular units are assembled and interlocked by application of the keyway to the adjacent side channels so as to form a single layer of modular units, a second layer of modular units can be formed onto the top thereof where the top and bottom channelled extrusions incorporating the keyway design, can also be utilised such that a horizontal interlocking plate 10 can be installed. In this manner, very large 25 window constructions can be built up incorporating the full interlocking facility of the invention so as to ensure totally rigid and integral window or architectural fitting can be built up. Referring to Figure 3 and 4 the manner in which the frames of the architectural fitting can be assembled is clearly shown in both a vertical and a horizontal orientation 30 and the modularity and integrity of the square elements is not lost by the building up of any number of units which in the built up configuration provide an exact finished size corresponding to the proportion of the individual modular units. Another advantage of the invention is the complete flexibility of each modular openable window unit incorporating a hinged infill window where the left and right 35 hinging can be set by simply rotating the module 180 degrees. Similarly, rotating a module through 90 degrees can convert and awning window into a casement window. 263313_1 6 In this manner, the architectural fitting of the invention provides architects, designers and builders with the ability to mix and match the separate modular components built up with the fitting of the invention into any number of sizes or configurations available within the combination provided by the fitting of the 5 invention. The end user will know immediately the size and configuration of the final finished and assembled modular units and the ability of the architectural fitting of the invention to provide a limited number of component parts for use and the modular build up of a given project allows the architectural fitting of the invention to be readily stopped and available for immediate despatch upon receipt of an order. 10 It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. 263313_1

Claims (10)

1. An architectural fitting of the type including windows and doors, said fitting comprising a generally rectangular frame housing an infill panel of glass or the like, said frame being formed of at least two lengths of a channel shaped extrusion having a 5 recessed base and two extending flanges at the inner and outer edges thereof, wherein said recessed base includes one or a plurality of negative keyways for captively receiving an intermediate locking plate such that said locking plate can co-operate to lock two adjacent frames by slidable engagement so as to remain captive and fully contained within the two adjacent recessed bases. 10

2. A fitting according to claim 1, wherein said frame is formed of three or four of said channel shaped extrusions.

3. A fitting according to claim 1 or 2, wherein said keyways are formed inboard 15 from said inner and outer edges so as to provide a fixing channel at or near said inner and outer edges for receiving fastening means to fix said channel lengths of a given frame together to make up said frame.

4. A fitting according to any one of claims 1 to 3, wherein said keyways are obular 20 shaped.

5. A fitting according to any one of claims I to 4, wherein said locking plate effects a snug sliding engagement of adjacent frames such that said inner and outer flanges of adjacent frames are brought into abutment. 25

6. A fitting according to any one of claims 1 to 5, wherein said intermediate locking plate is symmetrical in shape to allow engagement in any orientation.

7. A fitting according to any one of claims 1 to 6, wherein said locking plate 30 incorporates a seal configured to bridge adjacent frames and provide a sealable joint thereinbetween.

8. A fitting according to any one of claims 1 to 7, where said infill panel is double or triple glassed. 35 263313_1 8

9. A fitting according to any one of claims 1 to 8, wherein said infill panel is separately framed and hinged or otherwise fitted to said frame.

10. A fitting according to any one of claims 1 to 9, substantially as hereinbefore 5 described with reference to the figures. 263313_1