AU2009236042B2

AU2009236042B2 - Interconnection of a Mullion with a Window Frame or Door Frame or like Frame

Info

Publication number: AU2009236042B2
Application number: AU2009236042A
Authority: AU
Inventors: Ross Lloyd
Original assignee: Dowell Windows Pty Ltd
Current assignee: Dowell Windows Pty Ltd
Priority date: 2009-11-12
Filing date: 2009-11-12
Publication date: 2015-08-27
Anticipated expiration: 2029-11-12
Also published as: AU2009236042A1

Abstract

A method of interconnecting a mullion to a window frame or door frame or like frame is provided. The mullion is shaped at its top and bottom ends to form a butt joint with a head transom or sill of the frame. At least one key socket is provided in a laterally inwardly extending flange of the mullion. A corresponding 10 key part is provided on a transversely extending flange of the head, transom or sill together with a passageway. The laterally inwardly extending flange of the mullion is then laterally displaced relative to the head, transom or sill so the key part passes into the key socket. A mullion 15 block and optional spreaders are positioned within this interconnection between the mullion and head, transom or sill to support against wind loading or other forces which may cause deformation of the interconnection. The window or door frame or other like frame can then be glazed or 20 otherwise filled with a fitting to hold the mullion in the laterally displaced condition. 21118581 (GHMatlers) 12111109

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Standard Patent Applicant(s): CAPRAL ALUMINIUM LIMITED Invention Title: Interconnection of a Mullion with a Window Frame or Door Frame or like 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 OR LIKE FRAME 5 This invention relates to interconnection of a mullion to a window frame or a door frame or like frame (hereinafter referred to as "window frame"). Hitherto, mullions have been interconnected to a 10 window or door frame or like frame of extruded or roll formed metal by connecting either with the head and sill, or with the head 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 15 mullion has a finished joint appearance at the interconnection with the head, sill or transom. In other words, from the outermost weather side exposed face of the window or door frame, a finished joint with the mullion should appear neat. In pending Australian patent 20 application 2007211867 which has been assigned to us, there is disclosed a particular system for this interconnection. It has been found that improved features can be 25 obtained over and above those disclosed in the pending Australian patent application no. 2007211867 to minimise the effect of wind loading to the resultant window frame or door frame which may give rise to damage of the window frame or door frame at positions where the mullion 30 interconnects. Accordingly, the whole of the subject matter of the aforementioned specification 2007211867 is incorporated herein by reference. Therefore, according to a first broad aspect of 35 the present invention there is provided A method of interconnecting one end of a mullion to a window or door frame or like frame (hereinafter referred to as "window 21118581 (GHMatters) 12/11109 - 3 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 s frame so an outermost weatherside exposed face of the mullion will appear as butt jointed therewith and so there is one or more free flanges that extend transversely inwardly of the outermost weatherside face at the one end of the mullion, said one or more free flanges being 10 positioned to align with at least an outer laterally extending flange of the respective head, sill or transom, providing at least one key socket aperture in at least one of the one or more free flanges at a position proximate to the aligned laterally extending flange of the 15 respective head, sill or transom, providing a corresponding one or more passageways in the outer laterally extending flange of the respective head, sill, or transom, said one or more passageways each defining a laterally extending key part, 20 inserting the one or more free flanges of the mullion in the corresponding one or more passageways in the outer laterally extending flange of the respective one of the head sill, or transom to position the mullion so the key socket aperture is in alignment with the key part, 25 laterally displacing the mullion relative to the head, sill, or transom so the key part passes into said key socket, slidably moving a mullion block, slidably carried by the mullion, in a lengthwise direction of the mullion 30 so that the mullion block will overlap both the mullion and the key part and provide supporting contact with surfaces of the outer laterally extending flange that surround said key part to minimise against deformation of those surfaces caused by wind loading and consequent 35 deflection of said mullion by said mullion block supporting those surfaces, and then, glazing or otherwise filling the window 21118581 (GHMatters) 12/11109 - 4 frame with a filling so the glazing or filling holds the mullion in the laterally displaced condition. According to a further broad aspect of the 5 present invention there is provided A method of interconnecting one end of a mullion to a window or door frame or like frame (hereinafter referred to as "window frame"), said mullion and said window frame being of extruded or roll formed frame material, said method 10 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 butt jointed therewith and so there is one or more free flanges that extend transversely 15 inwardly of the outermost weatherside face at the one end of the mullion, said one or more free flanges being positioned to align with at least an outer laterally extending flange of the respective head, sill or transom, providing at least one key socket aperture in at 20 least one of the one or more free flanges at a position proximate to the aligned laterally extending flange of the respective head, sill or transom, providing a corresponding one or more passageways in the outer laterally extending flange of the 25 respective head, sill, or transom, said one or more passageways each defining a laterally extending key part, inserting the one or more free flanges of the mullion in the corresponding one or more passageways in the outer laterally extending flange of the respective one 30 of the head sill, or transom to position the mullion so the key socket aperture is in alignment with the key part, laterally displacing the mullion relative to the head, sill, or transom so the key part passes into said key socket, providing an extension part at at least one 35 end of said mullion to engage with a mullion spreader that engages with respective head or sill or transom to spread wind loading forces from the mullion to the respective 21118581 (GHMatters) 12/11/09 - 5 head or sill or transom over an area greater than without use of the spreader to minimise wind loading damage that may deform the respective head or sill or transom, then, glazing or otherwise filling the window frame 5 with a filling so the glazing or filling holds the mullion in the laterally displaced condition. In order that the invention can be more clearly ascertained examples of embodiments of the invention for 10 use with examples of embodiments disclosed in the aforementioned pending patent application no. 2007211867 will now be described wherein: Figure 1 is an isometric view of an end of a mullion 15 including a mullion block partly inserted into a channel in the mullion, Figure 2 is an isometric view from the opposite side in Figure 1 and showing the mullion block inserted further 20 into the channel in the mullion, Figure 3 is a view showing assembly of the mullion to a head in accordance with the teachings of an example of an embodiment of the aforementioned pending patent 25 application no. 2007211867, Figure 4 is a view showing the mullion block extended to the position shown in Figure 1 when the mullion is assembled to the head, 30 Figure 5 is an isometric view of the mullion block from a front side, Figure 6 is an isometric view of the mullion block 35 taken from a rear side, Figure 7 is a rear elevation view of the mullion 21118581 (GHMatters) 12J11/09 -6 block, Figure 8 is a side elevation view of the mullion block from one side, 5 Figure 9 is a side elevation view of the mullion block from the opposite side shown in Figure 8, Figure 10 is a front elevation view of the mullion 10 block, Figure 11 is a view of a different example of an embodiment showing a head having a mullion spreader partly inserted therein, 15 Figure 12 is a view similar to that in Figure 1 but for use in a different example, Figure 13 is a view similar to Figure 3 but for use 20 in this example, Figure 14 is a view similar to that of Figure 4 but for use in this example, 25 Figure 15 is a view showing positioning of the mullion spreader centrally over the mullion block in an assembled condition and; Figure 16 is a side elevation view of a sill showing 30 detail of how the mullion block engages with the mullion spreader and how the mullion spreader engages with a sill. Referring firstly to the example shown in the embodiment of Figures 1 - 10, reference should first be 35 made to the specification of the aforementioned pending patent application no. 2007211867. The end profile of the mullion with the required key socket aperture is disclosed 21118581 (GHMatters) 12/11/09 - 7 therein. The head, sill or transom will have laterally extending key parts formed therein as disclosed in the aforementioned pending patent application. In other words, the mullion, the head, and the sill or transom are s interconnected in this example in the same manner as disclosed in the aforementioned pending patent application. Like components to those disclosed in the aforementioned pending patent application will be described herein with the same reference numerals. New 10 components for the inventions disclosed herein will commence at reference numeral 101. In this example, the mullion does not have the cut-out 51 nor the locating surface 55 mentioned in the aforementioned pending patent application. Accordingly, in this example, the mullion 15 forms a neat butt joint with the head 1, sill 3, or transom 5 (which is otherwise identical to that in the aforementioned pending patent application). In this example, mullion block 101 is inserted into a channel in the mullion 23 that is formed between one or more 20 extending free flanges 41. The drawings do not clearly show the channel, however, the channel extends lengthwise of the mullion 23. Ribs may be extended laterally perpendicular to the one or more free flanges 41 to partly close the channel from a rear face of the mullion 23. In 25 this case, the mullion block 101 is an elongate generally rectangular shaped product that is arranged to be slidably received within the channel in the mullion. The detailed structure of the mullion block 101 will be described in due course. Figure 1 shows the mullion block 101 being 30 inserted into the channel at one end of the mullion 23. Figure 2 shows the mullion block 101 inserted to a position below the shaped end profile of the mullion 23. Figure 3 shows the mullion 23 with the mullion block 101 inserted to the position shown in Figure 2 immediately 35 prior to interconnection of the mullion 23 with the head 1. In this case, the free flange 41 passes through the passageway 49 and then the mullion can be moved 21118581 (GHMatters) 12/11109 - 8 transversely along the length of the head 1 to locate the free flange 41 in the lower part 59 (in this case an upper part). The arrangement is fully disclosed in the aforementioned pending patent application. When the 5 mullion 23 is correctly positioned and moved relative to the key socket 45 (see the aforementioned pending patent application) then the mullion block 101 can be extended outwardly from the end of the mullion 23 so the mullion block 101 will overlap both the mullion and the key part 10 61 and provide supporting contact with the surfaces of the outer laterally extended flange that surrounds the key part 61. With this arrangement, the key part 61 (see Figure 3) is supported in an area where it is weakened by the passageway 49 and the lower part 59 (in this case the 15 upper part). Accordingly, any wind loading that is applied to the window or door frame that may otherwise deform the head 1, sill 3 or transom 5 at the region of the passageway 49 and 20 the key part 61 will be minimised. It should be noted, that the surfaces of the head 1, sill 3, or transom 5, are between the mullion block 101 and the part of the mullion that overlies the outer laterally extending flange of the respective head 1, sill 3, or transom 5. Thus, the key 25 part 61 is supported. The mullion block 101 is shown in Figure 5 and comprises a generally elongate rectangular shape block made from a suitable material such as industrial grade 30 plastics. A mullion block 101 has main bearing faces 103 on opposed sides. The mullion block 101 has upper and lower extending arms 105 and 107. The upper and lower extending arms 105 and 107 are mirror images of each other. The arms 105 and 107 have respective engagement 35 faces 109 and 111 that engage with the inside faces of the laterally extending flanges of the head 1, sill 3, or transom 5 when the mullion block 101 is slidably moved in 21118581 (GHMatters) 12/11/09 -9 the mullion 23 to locate and overlap the key part 61. The faces 109 and 111 are therefore laterally inwardly displaced relative to the faces 103. s The leading edges at the free ends of the arms 105 and 107 can be slightly chamfered as shown to facilitate ease of insertion into the channels of the head 1, sill 3, or transom 5. Figure 5 and 10 show laterally extending ribs 113 and 115 that extend over the respective faces 109 10 and 111. The ribs 113, 115 have a width across the faces 109 and 111 corresponding to the width of the passageway 49 in the head 1, sill 3, or transom 5. Thus, when the mullion block 101 is slidably moved from the mullion 23 to locate behind the key part 61, a rib 113 or 115 will fill 15 the passageway 49. It should be therefore be seen that when the mullion block 101 is moved to support the key part 61 and the corresponding surfaces in that area, a substantially 20 enhanced integrity of construction can be afforded relative to that disclosed in the aforementioned pending patent application. Thus, wind loading forces imparted to the window or door frame can be accommodated to minimise the effects of wind loading deformation that may be caused 25 thereby. In other words, any deformation that is consequent on deflection of the mullion is minimised by use of the mullion block 101. It should be noted that the arms 105 and 107 are a 30 mirror image of each other to accommodate for insertion of the mullion block 101 into the channel in the mullion and for slidably moving either upwardly or downwardly relative to the mullion 23. Thus, a mullion block 101 can be provided for use for connection at an upper end of the 35 mullion 23 or at a lower end of a mullion 23. The mullion block 101 is provided with a plurality of 2111858_1 (GHMatlers) 12/11/09 - 10 upstanding shear ribs 117 that have a generally diamond shape configuration as shown. These may be provided at various locations on the outer surface of the mullion block 101. These are arranged to engage with the surfaces 5 around the channel in which the mullion block 101 is slidably received and to deform and shear to provide a tight snug fit of the mullion block 101 into the channel in the mullion. This, in turn, inhibits against unwanted or accidental sliding movement of the mullion block 101 10 relative to the mullion 23. This, in turn, holds the mullion block 101 in the extended position to engage and support the surfaces around the key part 61 and the corresponding surfaces of the laterally extending flanges that surround the key part 61. 15 Referring now to the embodiment shown in Figures 11 16, there is shown an example for distributing wind loading forces from the mullion to the respective head 1, sill 3 or transom 5 over an area greater than without use 20 of a spreader 119. The embodiment is substantially otherwise identical to the embodiment previously described. Here, a spreader 119 is formed from a suitable material such as extruded aluminium. The spreader 119 has a profile that enables insertion of the spreader 119 into 25 a glazing channel 121 in the head 1, sill 3, or transom 5. The glazing channel 121 is best shown in Figures 15 and 16. The spreader 119 may have any suitable cross sectional profile, however, the one depicted provides for economy of manufacture and minimal base manufacturing 30 material such as aluminium. Here, the profile has an upstanding central core flange 123 with an upper horizontally extending flange 125 and a lower horizontally extending flange 127. The upper horizontally extending flange 125 is provided near the uppermost edge of the 35 central core flange 123, whereas the lower horizontal extending flange 27 is provided at a position spaced intermediate the lowermost edge of the central core flange 21118581 (GHMatters) 12/11/09 - 11 123. The length of the spreader 119 is desirably equal to the width of the mullion 23, but it may be of any desired s length in order to provide enhanced wind loading distribution through the respective head 1, sill 3, or transom 5. It should be noted that the lowermost edge of the 10 central core flange 123 is provided with an angle offset rib 129. It should also be noted that in the preceding figures 1 - 10 the arms 105 and 107 of the mullion block 101 have a laterally extending slot 131 therein at the free ends. At the innermost end of the slot 131 there is 15 provided a laterally displaced offset cavity 133. The arrangement is such that when the mullion block 101 is slidably extended to the position shown for supporting the surfaces around the key parts 61, then the spreader 119 can be slid along the glazing channel 121 so that the 20 central core flange 123 can locate in the slot 131 BO the offset rib 129 will locate in the offset cavity 133. This is best shown in Figure 16. This, in turn, provides a frictional holding of the spreader 119 relative to the mullion block 101. Thus, by appropriately moving the 25 spreader 119 it can be positioned generally centrally of the width of the mullion 23. It should be noted that the free ends of the upper horizontally extending flange 125 and lower horizontally extending flange 127 loosely locate against the inside surfaces of the glazing channel 121. 30 Figure 16 shows that the spreader 119 has an innermost rib 135 extending along the free edge thereof. The rib therefore provides a greater surface area at this point for contacting with the inside surfaces of the glazing channel 121. It is also noted that the opposite end of 35 the upper horizontally extending flange 125, locates under a shoulder formed in the head 1, sill 3 or transom 5. 21118581 (GHMatters) 12/11/09 - 12 Accordingly, it can be seen that the mullion 23 is provided with an extension part (in this case the mullion block 101) that engages with the mullion spreader 119. The mullion spreader 119, engages with respective head 1, 5 sill 3, or transom 5 to spread wind loading forces from the mullion 23 to the respective head or similar transom over an area greater than that without use of the spreader 119. Thus, enhanced wind loading can be provided by using the spreader 119. 10 Modifications may be made to the examples of the embodiments shown above without departing from the ambit of the invention. For example, the cross sectional profile of the mullion block 101 and the spreader 119 may 15 be configured differently. The exact profiles are not critical to operation and performance of the respective inventions. In a variation, the mullion block 101 may be provided 20 to snap lock engage relative to the mullion and/or the head 1, sill 3 or transom 5 when in the extended position. Appropriately snap locking means may be provided either in the mullion 23 or in the head 1, sill 3 or transom 5 to accommodate for the snap locking arrangement. 25 These and other modifications may be made without departing from the ambit of the invention the nature of which is to be determined from the foregoing description. 30 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 of the common general knowledge in the art, in Australia or any other country. 35 In the claims which follow and in the preceding description of the invention, except where the context 21118581 (GHMatters) 12111/09 - 13 requires otherwise 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 5 not to preclude the presence or addition of further features in various embodiments of the invention. 21118581 (GHMatters) 12/11/09

Claims

1. A method of interconnecting one end of a mullion to a window or door frame or like frame (hereinafter s referred to as "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 butt jointed therewith and so there is one or more free flanges that extend transversely inwardly of the outermost weatherside face 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 at least one key socket aperture in at least one of the one or more free flanges at a position proximate to the aligned laterally extending flange of the 20 respective head, sill or transom, providing a corresponding one or more passageways in the outer laterally extending flange of the respective head, sill, or transom, said one or more passageways each defining a laterally extending key part, 25 inserting the one or more free flanges of the mullion in the corresponding one or more passageways in the outer laterally extending flange of the respective one of the head sill, or transom to position the mullion so the key socket aperture is in alignment with the key part, 30 laterally displacing the mullion relative to the head, sill, or transom so the key part passes into said key socket, slidably moving a mullion block, slidably carried by the mullion, in a lengthwise direction of the mullion 35 so that the mullion block will overlap both the mullion and the key part and provide supporting contact with surfaces of the outer laterally extending flange that 21118581 (GHMatters) 12/11/09 - 15 surround said key part to minimise against deformation of those surfaces caused by wind loading and consequent deflection of said mullion by said mullion block supporting those surfaces, s and then, glazing or otherwise filling the window frame with a filling so the glazing or filling holds the mullion in the laterally displaced condition.

2. A method as claimed in claim 1, wherein the one 10 or more passageway, each provide two keys that face each other so the mullion can be laterally displaced to the left or the right, to appropriate position the mullion laterally relative to the head, sill, or transom. 15

3. A window frame having a mullion interconnected by a method as claimed in any one of the preceding claims.

4. A window frame as claimed in claim 4, wherein said key part is covered by a part of said mullion when 20 said mullion is laterally displaced when said key part passes into said key socket so said surfaces that surround said key part are between said mullion block and said part of said mullion. 25

5. A window frame as claimed in any one of claims 1 to 4, wherein said mullion block has surfaces that have been deformed consequent on said mullion block being slidably moved relative to said mullion, whereby to provide friction engagement with said mullion. 30

6. A window frame as claimed in any one of claims 1 to 5, wherein said mullion block comprises a rib that is located in at least one of said passageways when the mullion block has been slidably moved to overlap the key 35 part.

7. A window frame as claimed in any one of claims 3 21118581 (GHMatters) 12/11/09 - 16 and 6, and substantially as herein described with reference to the accompanying drawings.

8. A method as claimed in claim 1 or claim 2, and 5 substantially as herein described with reference to the accompanying drawings.

9. A method of interconnecting one end of a mullion to a window or door frame or like frame (hereinafter 10 referred to as "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 15 exposed face of the mullion will appear as butt jointed therewith and so there is one or more free flanges that extend transversely inwardly of the outermost weatherside face at the one end of the mullion, said one or more free flanges being positioned to align with at least an outer 20 laterally extending flange of the respective head, sill or transom, providing at least one key socket aperture in at least one of the one or more free flanges at a position proximate to the aligned laterally extending flange of the 25 respective head, sill or transom, providing a corresponding one or more passageways in the outer laterally extending flange of the respective head, sill, or transom, said one or more passageways each defining a laterally extending key part, 30 inserting the one or more free flanges of the mullion in the corresponding one or more passageways in the outer laterally extending flange of the respective one of the head sill, or transom to position the mullion so the key socket aperture is in alignment with the key part, 35 laterally displacing the mullion relative to the head, sill, or transom so the key part passes into said key socket, providing an extension part at at least one 21118581 (GHMatters) 12/11109 - 17 end of said mullion to engage with a mullion spreader that engages with respective head or sill or transom to spread wind loading forces from the mullion to the respective head or sill or transom over an area greater than without 5 use of the spreader to minimise wind loading damage that may deform the respective head or sill or transom, then, glazing or otherwise filling the window frame with a filling so the glazing or filling holds the mullion in the laterally displaced condition. 10

10. A method as claimed in claim 9, wherein the one or more passageway, each provide two keys that face each other so the mullion can be laterally displaced to the left or the right, to appropriate position the mullion 15 laterally relative to the head, sill, or transom.

11. A window frame having a mullion interconnected by a method as claimed in any one of the preceding claims. 20

12. A window frame as claimed in claim 11, wherein said key part is covered by said mullion when the mullion is laterally displaced when said key part passes into said key socket. 25

13. A window frame as claimed in claim 12, wherein said mullion spreader is engaged within a glazing channel in said respective head or sill or transom.

14. A window frame as claimed in claim 13, wherein 30 said mullion spreader has a longitudinally extending flange which is received in a slot in an end of said extension part and wherein said engagement is by said flange being received in said slot. 35

15. A window frame as claimed in any one of claims 12 to 14, wherein said extension part is a mullion block slidably carried by the mullion to move in a lengthwise 2111858_1 (GHMatters) 12/11/09 - 18 direction of said mullion.

16. A window frame as claimed in claim 15, wherein said mullion block overlaps both the mullion and the key s part and provides support contact with surfaces of the outer laterally extending flange that surround said key part to minimise against deformation of those surfaces by wind loading and consequent deflection of said mullion by said mullion block supporting those surfaces. 10

17. A window frame as claimed in claim 16, wherein said key part is covered by a part of said mullion when said mullion is laterally displaced when said key part passes into said key socket so said surfaces that surround 15 said key part are between said mullion block and said part of said mullion.

18. A window frame as claimed in any one of claims 15 to 17, wherein said mullion block has surfaces that have 20 been deformed consequent on said mullion block being slidably moved relative to said mullion, whereby to provide friction engagement with said mullion.

19. A window frame as claimed in any one of claims 15 25 to 18, wherein said mullion block comprises a rib that is located in at least one of said passageways when the mullion block has been slidably moved to overlap the key part. 30

20. A window frame as claimed in any one of claims 11 to 19, and substantially as herein described with reference to the accompanying drawings.

21. A method as claimed in claim 9 or claim 10, and 35 substantially as herein described with reference to the accompanying drawings. 21118581 (GHMatters) 12/11/09