AU2010100210A4 - Composite window or door assembly - Google Patents

Description

- 1 AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION FOR AN INNOVATION PATENT ORIGINAL Name of Applicant: Trend Windows & Doors Pty Limited Actual Inventors: Paul Jordan and Mike Palin Address for Service is: SHELSTON IP 60 Margaret Street Telephone No: (02) 9777 1111 SYDNEY NSW 2000 Facsimile No. (02) 9241 4666 CCN: 3710000352 Attorney Code: SW Invention Title: COMPOSITE WINDOW OR DOOR ASSEMBLY The following statement is a full description of this invention, including the best method of performing it known to us: File: 64218AUP00 -2 COMPOSITE WINDOW OR DOOR ASSEMBLY FIELD OF THE INVENTION The present invention relates generally to building systems. More particular, the 5 invention relates to windows and doors for use in residential, commercial and industrial buildings. The invention has been developed primarily for use as a composite window or door assembly and will be described hereinafter with reference to this application. BACKGROUND OF THE INVENTION 10 Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field. Residential, commercial and industrial buildings commonly include several windows and doors which are hingedly or slidably mounted to a window frame such that 15 the window can move between closed and open positions. Hingedly connected windows are generally classified into two main categories, namely casement windows and awning windows, based on the location of the hinge or hinges. Casement windows are typically hinged along their left or right side frame members. Awning windows are usually hinged along their upper or top frame member, 20 however, in some forms can be hinged along their lower or bottom frame member. Slidably mounted windows and doors, including multi-fold designs, typically are used in larger window and door openings having a wider span. Such windows and doors as used in typical residential, commercial and industrial buildings commonly suffer from out dated designs and do not adequately meet the 25 thermally efficiency or performance requirements of building regulations.

-3 It is an object of the present invention to overcome or substantially ameliorate one or more of these disadvantages of the prior art, or at least to provide a useful alternative. SUMMARY OF THE INVENTION 5 According to the invention, there is provided a composite window or door assembly for an opening in a wall of a building, the composite assembly including: a frame mountable within the wall opening, the frame having metal outer frame members and a thermoplastic inner lining disposed over substantially all of the inside faces of the outer frame members so as to extend around the periphery of the frame; 10 wherein, the outer frame members and the inner lining act in combination to form an uninterrupted composite insulating barrier about the periphery of the frame. Preferably, the composite window or door assembly includes a sash mounted to the frame, the sash having a metal outer sash frame for holding a window pane, and a thermoplastic inner sash lining disposed over substantially all of the inside faces of the 15 metal outer sash frame. In other preferred embodiments, the window pane can be held directly in the frame, more particularly the metal outer frame members. In such embodiments, the window or door assembly can include two or more frames positioned adjacent each other, preferably such that one frame is movable relative to the other frame to open or 20 close the window assembly. In certain preferred embodiments, the sash is mounted to the frame such that the sash is selectively movable relative to the frame between an open position and a closed position. In some preferred forms, the sash is slidably movable relative to the frame to which it is mounted. In other preferred forms, the sash is hingedly movable relative to 25 the frame.

-4 Preferably, the metal outer frame members are formed of aluminium. The metal outer frame members are preferably extruded. Preferably, the metal outer frame members have a constant cross-sectional profile. In certain preferred forms, the metal outer frame members have an open or channelled cross-sectional profile for reducing the 5 occurrence of heat pockets with the frame of the window assembly. In some preferred forms, only a portion of the cross-sectional profile of each metal outer frame members is open or channelled. Preferably, the cross-sectional profile of the metal outer frame members is one of L- or U-shaped. The thermoplastic cover lining is preferably formed of polyvinyl chloride (PVC), 10 more preferably unplasticised polyvinyl chloride (uPVC). The thermoplastic cover lining is preferably formed of two or more interconnected lining members. Preferably, the lining members have a constant cross-sectional profile. The lining members are preferably extruded. Preferably, the profiles of the metal outer frame members and the lining members 15 have complementary mating formations for mounting the lining members on the frame members such that the lining members cover the inside faces of the outer frame members. The lining members preferably cover the entirety of the inside faces of the outer frame members. In some preferred forms, the window assembly includes sealing means arranged to 20 provide sealing between the frame and the sash when the sash is in the closed position. The sealing means is preferably in the form of a rubber sealing element disposed to extend around the marginal edges of the sash. Preferably, the sealing element is mounted to one of the frame and the sash. In some preferred forms, the sealing means includes two sealing elements. In such embodiments, one sealing element is preferably - 5 mounted to the frame, and other sealing element is preferably mounted to the sash. The sealing member mounted to the frame can be mounted to the inner lining. In various preferred embodiments, the frame includes a sealing frame member mounted to one of the outer frame member such that the sash can abut against the 5 sealing frame member when the sash is in the closed position. Preferably, the sealing frame member is formed of aluminium. It will be appreciated that the uninterrupted composite insulating barrier advantageously improves the thermal efficiency or rating of the window or door assembly. Preferably, the composite insulating barrier is configured to provide the 10 window or door assembly with a National Fenestration Rating Council (NFRC) Uw value, hereinafter Uw-value, in the range from approximately 2 W/m 2 .K to approximately 7 W/m 2 .K. In certain preferred embodiments, the Uw-value is in the range from approximately 3 W/m 2 .K to approximately 5 W/m 2 .K. In other preferred embodiments, the Uw-value is in the range from approximately 4 W/m 2 .K to 15 approximately 6 W/m 2 .K. In some preferred forms, the window assembly is one of a fixed window, a double hung window, a casement window, and an awning window. Those skilled in the art will appreciate that casement windows are generally hinged on a substantially vertical side member of the window. That is, casement windows are generally hinged on either the 20 left or the right side of the window. Awning windows are typically hinged along a top edge member of the window. In other preferred forms, the window assembly is one of a fixed door, a sliding door, a hinged door, a bi-fold or multi-fold door. In certain embodiments, the window assembly is a single glazed window. In other 25 preferred forms, the window assembly is a double glazed window.

- 6 BRIEF DESCRIPTION OF THE DRAWINGS Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a cross-sectional view of a corner of an embodiment of a single glazed 5 window assembly according to the invention; Figure 2 is a cross-sectional view of a corner of an embodiment of a double glazed window assembly according to the invention; Figure 3 is a side view of an embodiment of a sliding window assembly according to the invention, configured for vertical sliding movement; and 10 Figure 4 is a side view of an embodiment of a sliding window assembly according to the invention, configured for horizontal sliding movement. PREFERRED EMBODIMENTS OF THE INVENTION Referring to the drawings, the present invention provides a composite window 15 assembly I for an opening 2 in a wall of a building (not shown). It will be appreciated by those skilled in the art that the invention can be applied equally to both window and door assemblies. However, to simplify the description so that it may be better understood, the following description will be made with reference to windows only. Referring firstly to the embodiment shown in Figure 1, the composite window 20 assembly I includes a frame 4 is mounted within the wall or window opening 2 of the building. The frame 4 is mounted to, or adjacent to, a timber reveal 3 fitted about the window opening. The frame 4 is formed of four interconnected extruded aluminium outer frame members 5. The frame members 5 are connected to match the shape of the wall opening 2. The window opening 2 and thus the frame 4 is preferably square or 25 rectangular in shape.

-7 It will be appreciated, however, that the frame is not limited to square or rectangular shapes and can be configured into many different polygonal shapes to suit various desired window and building designs. A thermoplastic inner lining 6 formed of extruded unplasticised polyvinyl chloride 5 (uPVC) is fixedly mounted so as to cover substantially all of the inside faces 7 of the outer frame members 5. The thermoplastic cover lining is formed by four interconnected lining members 6, each having a constant cross-sectional profile. The uPVC inner lining 6 is arranged to extend around the periphery of the frame 4, against the edges of the wall opening 2, such that the outer frame members 5 and the 10 inner lining 6 act in combination to form an uninterrupted composite insulating barrier about the periphery of the frame 4. In the embodiments shown in Figures 1 and 2, the composite window assembly 1 includes a sash 8 hingedly mounted to the frame 4 such that the sash 8 can be selectively moved relative to the frame 4 between an open position and a closed position, as desired. 15 The sash 8 of the singled glazed window of Figure 1 has a metal outer sash frame 9 for holding a single glass window pane 10. In the double glazed composite window assembly of Figure 2, the metal outer sash 10 is adapted to hold two glass window panes 10. A spacer I I is arranged between the two glass panes 10 in order to hold the panes in generally parallel spaced apart relationship to each other. 20 Referring now to Figures 3 and 4, two embodiments of sliding window assemblies are shown. In these embodiments, the window pane 10 is held directly in the outer frame members 5 of the frame 4. These sliding window assemblies I include two frames 4 positioned adjacent to, but offset from each other, for facilitating relative sliding movement of the frames 4.

-8 One frame 4 is preferably mounted in a fixed position in the wall opening 2, while the other can be slid between an open and closed position, as desired. As shown in Figures 3 and 4, each frame 4 of the sliding window assemblies I has aluminium outer frame members 5 with respective rear faces each covered with its own 5 inner lining 6 such that each section of the sliding window assembly I has an uninterrupted composite insulating barrier bounding its respective marginal edges. As clearly shown in the drawings, the extruded aluminium outer frame members 5 have a constant cross-sectional profile. Figures 1 and 2 show particularly advantageous embodiments of the window assembly I in which the frame members 5 have a generally 10 open or channel-shaped profile portion 12. The channel-shaped portion 12 is arranged to face outwardly so as to reduce the occurrence of undesirable heat pockets building up within the frame 4 of the window assembly 1. With reference to the drawings, it can be seen that the cross-sectional profiles of the aluminium outer frame members 5 and the uPVC lining members 6 have 15 complementary mating formations for mounting the lining members 6 onto the rear faces of the frame members 5 to cover the entirety of the inside faces of the outer frame members. As shown in Figures 1 and 2, the window assembly I includes sealing means in the form of two rubber sealing element (13, 14) arranged to provide sealing between the 20 frame 4 and the sash 8, when the sash 8 is in the closed position. The first rubber sealing element 13 is fitted to a complementary shaped groove in the inner lining 6 of the frame 4 and is arranged to extend around the marginal edge of the frame 4. The second rubber sealing element 14 is fitted to a complementary shaped groove in the sash 8 and is arranged to extend around the marginal edge of the sash 8, when the sash 8 is in the -9 closed position. The second rubber seal 14 is arranged to be outwardly of, and bound, the first rubber seal 13 such that the seals (13, 14) operate independently of each other. Referring again to Figures 1 and 2, the frame 4 also includes an aluminium sealing frame member 15 mounted to the outer frame member 5 adjacent to the unhinged sash 5 frame member such that the second rubber seal 14 sash 8 can sealingly abut against the sealing frame member 15, when the sash 8 is in the closed position. It will be appreciated that, in use, the uninterrupted composite insulating barrier advantageously improves the thermal efficiency or rating of the window assembly 1. The composite insulating barrier can be configured to provide the window assembly 10 with a Uw-value in the range from approximately 2 W/m2 .K to approximately 7 W/m 2 .K. Those skilled in the art will appreciate that the window assembly 1 can be configured to provide a desired or predetermined Uw-value for a particular application. It will be appreciated, however, that other Uw-values can be achieved to meet the particular thermal requirements of a building and that the window assembly could be 15 designed to have a Uw-value of, for example, approximately 2, 2.5, 3, 3.5, 4, 4.5 or 2 5 W/m2.K. Accordingly, the present invention, at least in its preferred embodiments, provides a simple, easy to manufacture and inexpensive composite window or door assembly. The composite window or door assembly advantageously provides improved thermal 20 properties and is suitable for in a wide variety of building applications, as well as being readily adaptable to the strict requirements imposed by industry building codes. In particular, preferred forms of the invention can be advantageously configured to reduce the occurrence of heat pockets from building up within the frame of the window assembly. In these and other respects, the invention in its preferred embodiments 25 represents a practical and commercially significant improvement over the prior art.

-10 Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims (5)

1. A composite window or door assembly for an opening in a wall of a building, the composite assembly including: a frame mountable within the wall opening, the frame having metal outer frame 5 members and a thermoplastic inner lining disposed over substantially all of the inside faces of the outer frame members so as to extend around the periphery of the frame; wherein, the outer frame members and the inner lining act in combination to form an uninterrupted composite insulating barrier about the periphery of the frame. 1o

2. A composite window or door assembly according to claim 1, including a sash mounted to the frame, the sash having a metal outer sash frame for holding a window pane, and a thermoplastic inner sash lining disposed over substantially all of the inside faces of the metal outer sash frame. 15

3. A composite window or door assembly.according to claim 2 wherein, the sash is mounted to the frame such that the sash is selectively movable relative to the frame between an open position and a closed position.

4. The composite window or door assembly according to claim 1, wherein the metal 20 outer frame members are formed of aluminium and the thermoplastic cover lining is formed of unplasticised polyvinyl chloride.

5. The composite window or door assembly according to any one of the preceding claims, wherein the composite insulating barrier is configured to provide the assembly 25 with a Uw-value in the range from approximately 2 W/m2.K to approximately 2 7 W/m .K.