AU2012244096B1 - Frame and cladding adapter - Google Patents

Abstract

C \NRPrbIN)CC\CAB\4(w7I12.1 DOC.5/I W2012 An adapter for fitting to a window frame, the adapter including a main body to sit against the frame, a connector to lock the adapter onto the frame and a flange to project laterally of the frame at a location spaced from an outer peripheral section of the frame, so as to extend between an underlying wall structure and cladding applied over the wall structure, the flange and body presenting a waterproof barrier around the frame.

Description

Australian Patents Act 1990 - Regulation 3.2 ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Invention Title Frame and cladding adapter The following statement is a full description of this invention, including the best method of performing it known to me/us: P/00/0 1l 5 102 C \NRPorbl\DCC\CAB\4667112_1.DOC-15/10/2012 FRAME AND CLADDING ADAPTER Related Application 100011 This application claims priority from Australian Patent Application No. 2012902153, the entire contents of which are incorporated herein by reference. Field of the Invention 100021 The present invention relates to a frame particularly, but not exclusively, a window frame. The invention also relates to a cladding adapter. Background of the Invention 100031 Figures 1 to 6 illustrate a known process for mounting a window frame 1 in a wall structure 2. 100041 Referring firstly to Figure 1, the window frame 1 is formed of a main frame section 3 fixed in a window reveal 4 of the wall structure 2. In this case, the window reveal 4 has a depth of 100mm. The frame has an outer peripheral section 5 that projects outwardly of the window reveal 4. 100051 With reference to Figure 2, a thermally insulating material, known as sarking, 6 is laid over the wall structure 2 and is cut to fit with the frame 1. [00061 With reference to Figure 3, strips of weather proof membrane 13 are positioned alongside the window jambs 7 and sill 8 of the frame 1 and are fixed in place, generally by stapling to the underlying wall structure 2.

C NRPorbhDCC\CAB\4914317_iDOC.7/O2O 3 -2 100071 With reference to Figure 4, a primed pine window surround 9 is fastened to the frame 1. In Figure 5 a pressed Colorbond @ head flashing 10 is shown placed over a head 11 of the frame 1. The flashing 10 is secured in place, such as by being stapled to the underlying wall structure 2. 100081 In Figure 6, the final installation 12 is shown, where cladding 14 is added and caulking and paint is applied, as required. 100091 A problem with the installation illustrated in Figure 6 is that although the window frame 1 may appear to be properly sealed there is, in fact, no reliable weatherproof seal between the window frame I and the surrounding wall structure 2. The sarking 6 is in general not properly sealed against the window frame I and there may, in any event, be gaps that are not properly caulked. The flashing 10 may not be fitted properly and, in some cases, a tradesman may even forget to install the flashing 10. With the described installation 12, there are too many opportunities for gaps to exist between the window frame and the building structure 2 and it only takes a small gap to allow water penetration that could cause considerable damage to the building structure 2 and surrounds. Object of the Invention [00101 The present invention seeks to address or at least ameliorate some of the above problems. Summary of the Invention [00111 In accordance with the invention, there is provided an adapter for fitting to a window frame, the adapter including a main body to sit against the frame, an integrally formed connector to lock the adapter onto the frame and a flange to project laterally of the frame at a location spaced from an outer peripheral section of the frame, so as to extend between an underlying wall structure and cladding applied over the wall structure, the flange and body presenting a waterproof barrier around the frame, wherein the connector C WNPorbl\DCC\CAB4914317 DOC.702/2013 -3 includes two parallel legs that snap fit over a corresponding connecting finger of the window frame and wherein an outer one of the legs extends over and covers the connecting finger of the window frame to form an outer face of the window frame so that the adapter presents an aesthetically seamless fit with the window frame. 100121 Preferably, the flange has an angled lip arranged to resiliently bear against the wall structure. 100131 No text here 100141 No text here [00151 Preferably, the adapter includes a pip that projects lengthwise and rearward of the flange in order to provide additional strength to the flange and locate on a reveal fin of the window frame. 100161 In another aspect, there is provided a window assembly with a window frame and an adapter, as described above, fitted to the frame. [00171 Preferably, one or more adapters are fitted around the frame, to a head, sill and jambs of the frame, to provide a substantially continuous weatherproof barrier around the window frame. 10017a] In another aspect, there is provided a window assembly with a window frame and one or more adapters fitted around the frame prior to installation in a building structure, to provide a substantially continuous waterproof barrier around the window frame, wherein the or each adapter includes a main body to sit against the frame, an integrally formed connector to lock the adapter onto the frame and a flange to project laterally of the frame at a location spaced from an outer peripheral section of the frame, so as to extend between an underlying wall structure and cladding applied over the wall structure, the flange and body presenting a waterproof barrier around the frame.

C \NRPorbl\DCC\CAB\491417.1 DOC-7/M2/23II -4 [00181 In another aspect, there is provided a method of manufacturing a pre-fabricated window assembly including forming a window frame and securing one or more adapters to the frame prior to delivery to a building site where the window assembly is fitted into a building structure, wherein the or each adapter includes a main body to sit against the frame, an integrally formed connector to lock the adapter onto the frame and a flange to project laterally of the frame at a location spaced from an outer peripheral section of the frame, so as to extend between an underlying wall structure and cladding applied over the wall structure, the flange and body presenting a waterproof barrier around the frame, wherein the connector includes two parallel legs that snap fit over a corresponding connecting finger of the window frame and wherein an outer one of the legs extends over and covers the connecting finger of the window frame to form an outer face of the window frame so that the adapter presents an aesthetically seamless fit with the window frame. 100191 In yet another aspect, there is provided a building including a building structure with a window assembly, as described above, fitted to the frame whereby the flange of the or each adapter sits adjacent the building structure and between the building structure and cladding applied over the building structure. 100201 Preferably, the building includes a thermal insulation membrane arranged over the building structure, wherein the membrane is bonded directly to the or each flange in order to provide a weatherproof seal between the membrane and the or each adapter. 100211 In another aspect, there is provided method of forming the building, including: fitting a prefabricated window assembly, as described above, into the building structure; covering the building structure with a weatherproof membrane and attaching the membrane to the barrier provided around the window assembly; and fitting cladding over the building structure, barrier and membrane.

C:NR.Ponbl\DCC\CAB\4914317_1 DOC-7102/2013 - 4a Brief Description of the Drawings [0022] The invention is more fully described with reference to the accompanying drawings, in which: Figure 1 is a partial perspective view of a prior art building structure and window frame; Figure 2 is a partial perspective view of the prior art building structure fitted with sarking; Figure 3 is a partial perspective view of the prior art building structure fitted with strips of waterproof membrane; Figure 4 is a partial perspective view of the prior art building structure and window frame fitted with a window surround; C.\NRPonbl\DCC\CAB\46671121 DOC-1/3I12012 -5 Figure 5 is a partial perspective view of the prior art building structure and window frame fitted with a head flashing; Figure 6 is a partial perspective view of a prior art installation including cladding; Figures 7a is a plan view of an adapter; Figure 7b is a bottom view of the adapter; Figure 7c is a rear isometric view of the underside of the adapter; Figure 7d is a side view of the adapter; Figure 8 is an enlarged side view of the adapter; Figure 9 is a cross sectional view of a sliding window head and adapter; Figure 10 is a cross sectional view of a sliding window jamb and adapter; Figure 11 is a cross sectional view of a sliding window sill and adapter; Figure 12 is an isometric view of the a sliding window fitted with an adapter; Figure 13 is a perspective view of the window and adapter fitted into a building structure; Figure 14 is a perspective view similar to Figure 13, showing cladding over the building structure; Figure 15 is an enlarged partial cross sectional view of the window and adapter fitted with cladding; C \N ortbl\DCC\CABWA667112_ .DOC.15/1(V2012 -6 Figure 16 is a perspective view of another example of an adapter fitted to a window frame; Figure 17 illustrates waterproof membrane being adhered to the adapter; Figure 18 illustrates the neat aesthetic finish achieved using the adapter; Figure 19 illustrates a three step process of installing a waterproof window assembly; Figure 20 illustrates comparative savings associated with the invention, compared to the prior art installation. Detailed Description of the Invention 100231 Referring firstly to Figures 7a to 7d, an adapter 20 is shown as including a generally rectangular shaped elongate body 21. The body 21 has an upper surface 22 and a lower surface 23. A flange 24 projects from the upper surface 22, substantially at right angles to the body 21 and along one edge 25. 100241 The flange 24 has a length dimension "L" greater than the length of the body 21 in order to define a wing extension 26 at either end of the body 21. 100251 An angled lip 27 is formed along a free edge of the flange 24 and a small pip 28 runs parallel to the lip 27, along the length of the flange 24, at a height of about half the total height "H" of the flange 24. 100261 A connector 26 projects from the lower surface 23, adjacent an opposite edge 28 of the body. The connector 26 includes two generally parallel legs 29, 30 with the outer leg 29 being longer than the inner leg 30.

C WRPortblDCC\CAB66712_1 DOC-15110/2012 -7 [00271 The adapter 20 is preferably formed by a process of either metal extrusion or plastic extrusion and is of a material impervious to water. [00281 Referring now to Figure 8, an enlarged end view of the adapter 20 is provided. The height "H" of the flange is preferably in the order of 50mm. The angled formation of the lip 27 provides strength to the flange, as does the pip 28. 100291 Each of the legs 29, 30 is formed with a small diameter recess 31 at the junction of the respective leg 29, 30 and the body 21. The recess 31 provides increased flex to each of the legs 29, 30. The inner leg 30 has an additional catch 32 that enables the connector 26 to act as a snap-fit connector. 100301 Referring now to Figure 9, the adapter 20 is shown fitted to part of a window frame 40, in this case a window head 41. The frame 40 has an inner section 42 that fits within a timber reveal 43 and an outer section 44 protruding outwardly from the reveal 43. 100311 The outer section 44 has a fin 45 that abuts the reveal 43 and a channel 46 that is closed by the adapter 20 when the body 21 sits against the frame 40, in a generally horizontal orientation. [00321 In that position, the connector 26 is snap fitted onto an upstanding finger 47. The catch 32 of the inner leg 30 captures a hooked end 48 of the finger 47 while the outer leg 29 sits snugly to cover the finger 47 all the way down to a peripheral section 49 of the frame 40. The adapter 20 is further supported by the pip 28 that rests on either the fin 45 or against the reveal 43 in order to securely locate the adapter relative to the frame 30. 100331 As can be seen, the flange 24 projects a substantial distance above the reveal when the adapter is snap fitted in place, to thereby provide a weatherproof barrier 50 along and laterally above the window head 41.

C NRonbl\DC\CABW667112-.DOC.15/1(V2012 -8 [00341 Referring now to Figure 10, an adapter 20 is shown attached to a sliding window jamb 51 that forms part of the same window frame 40. The jamb 51 has a different cross section compared to the head 41 however common features are provided to allow for connection of the adapter 20. Like parts are denoted with like reference numerals. In particular, the jamb 51 has an outer section 44 with a fin 45, a channel 46 that is covered by the adapter 20 and a hooked finger 47 projecting from an outer peripheral section 49 of the frame 40. 100351 As with the head 41, the flange 24 associated with the jamb 51 projects a substantial distance beyond the reveal 43 in order to provide a waterproof barrier 50 along and laterally to the side of the reveal. 100361 Referring now to Figure 11, an adapter 20 is shown attached to a sliding window sill 52. As with the head 41 and jamb 51, the sill 52 forms part of a common window frame 40 and like parts are denoted with like reference numerals. The sill 52 includes a fin 45 that abuts the reveal 43 and the same shaped channel 46 and hooked finger 47. The adapter 20 sits over the channel 46 with the connector 26 snap fitted onto the finger 47 so that the pip 28 abuts the fin 45 and the body 21 closes the channel 46. In that position, the flange 24 projects laterally and downward of the sill 52 to provide a barrier 50 along the length of the sill 52. [00371 Referring now to Figure 12, a window assembly 60 is shown formed of the entire frame 40 with an adapter 20 fitted to each of the head 41, jambs 51 and sill 52 so that the flanges 24 of each of the adapters 20 project laterally of the frame 40 from a location spaced from the outer peripheral section 49. 100381 The flange 24 associated with the head 41 is illustrated with the wing extensions 26 arranged to overlap the jamb flanges 24. Alternatively, the jamb flanges are cut to measure so there is no overlap. The window assembly 60 is preferably constructed as a prefabricated unit that is transported with the adapters 20 already in place. The individual adapters 20 can alternatively be formed as a single adapter piece fitted to the frame 40 C.\NRrb\DCC\CAB\466712_ I DOC-I51O/2OI12 -9 prior to transport. 100391 Referring now to Figure 13, an installation or building 53 is shown that includes building structure 54, of which the reveal 43 forms part, the window assembly 60 and cladding 55. The frame 40 is mounted in the window reveal 43 so that the flange 24 and, in particular, the lip 27 resiliently abuts the building structure 54. The flange 24 is thereby recessed away from the outer peripheral section 49 of the frame, to accommodate the cladding 55 fitted around the window frame 40. [00401 Figure 14 more clearly shows the cladding 55 in place, with the adapters 20 providing the barrier 50 that extends laterally and around the window frame 40, between the cladding 54 and the building structure 53. [0041] Referring to Figure 15, the positioning of the barrier 50 between the cladding 55 and the building structure 54 is more apparent. The manner in which the front leg 29 of the adapter 20 covers the outer peripheral section 49 of the frame 40 is also apparent and it can be seen that the adapter 20 provides a neat and aesthetically seamless finish to the front of the window assembly 60. [00421 Referring to Figure 16, a corner of the window assembly 60 is illustrated, where two adapters 20, associated with the head 41 and jamb 51, are overlapped. Alternatively, the adapters 20 can be mitred to fit together, as required. [00431 In Figure 17, an additional component of the installation or building 53, in the form of a flexible membrane 56, is illustrated. The membrane is preferably formed of an insulation material to provide improved thermal characteristics to the building. During the construction phase, the membrane 56 is cut to size, to fit over the window assembly 60 and is then bonded to the barrier 50 provided by the adapters 20. The flange 24 of each adapter 20 provides an ideal flat surface for adhering the membrane 56 to. The membrane 56 needs to be fixed in place by adhesive, such as polyurethane sealant/adhesive or the like, prior to the cladding 54 being fitted.

C \NRPonblDCC\CAB\M671121.DOC-15/I0/2012 - 10 100441 As may be appreciated, once the membrane 56 is fixed or adhered to the barrier 50 the building structure 54 around the frame 40 is effectively sealed or substantially sealed against weather and water ingress. [00451 With reference to Figure 18, the neat finish of the outer leg 29 covering the outer peripheral section 49 is apparent. In light of that aesthetically pleasing finish, there is no need to add an additional window surround, as used with the prior art construction. 100461 Turning now to Figure 19, installation and construction of the building 52 around the window assembly 60 is illustrated as being achieved in only three main steps A to C. The first step A is to simply secure the window assembly 60 in the building structure 54. The second step B is to apply and seal the membrane or sarking 56 to the window assembly 60. The third step C is then to simply clad, caulk and paint. [0047] This three-step process saves a considerable amount of time and money and actually provides a product with a reliable seal around the window frame 40, as compared to the prior art construction method. [00481 Figure 20 illustrates a comparison of costs associated with the prior art construction, as compared to the use of the present invention, referred to as the "Skywide" system. As can be seen, the present invention leads to considerable savings and a more reliable waterproof outcome. [0049] The invention has been described by way of non-limiting example only and many modifications and variations can be made without departing from the spirit and scope of the invention described. By way of example, the invention has been described with reference to mounting a window in a building structure. However, the adapter also has application to any framed opening where a weather seal is needed, such as around a panel or door. Accordingly, the word window should be construed as including such structures as doors or panels, or the like.

C :WRPorbl\DCC\CAB\4667112_1 DOC-13/10/2012 -*11 List of Parts 1. Window frame 2. Wall structure' 3. Main section 4. Window reveal 5. Peripheral section 6. Material 7. Window jamb 8. Sill 9. Surround 10. Head Flashing 11. Head 12. Installation 13. Membrane 14. Cladding 20. Adapter 21. Body 22. Upper surface 23. Lower surface 24. Flange 25. Edge 26. Wing extension 27. Lip 28. Pip 29. Leg 30. Leg 31. Recess 32. Catch 40. Window frame 41. Head C .\RPonbl\DCC\CABW667l12_1 DOC-15/12012 - 12 42. Inner section 43. Reveal 44. Outer section 45. Fin 46. Channel 47. Finger 48. Hooked end 49. Outer peripheral section 50. Barrier 51. Jamb 52. Window sill 53. Building 54. Building structure 55. Cladding 56. Membrane 60. Window assembly

Claims (15)

1. An adapter for fitting to a window frame, the adapter including a main body to sit against the frame, an integrally formed connector to lock the adapter onto the frame and a flange to project laterally of the frame at a location spaced from an outer peripheral section of the frame, so as to extend between an underlying wall structure and cladding applied over the wall structure, the flange and body presenting a waterproof barrier around the frame, wherein the connector includes two parallel legs that snap fit over a corresponding connecting finger of the window frame and wherein an outer one of the legs extends over and covers the connecting finger of the window frame to form an outer face of the window frame so that the adapter presents an aesthetically seamless fit with the window frame.

2. The adapter of claim 1, wherein the flange has an angled lip arranged to resiliently bear against the wall structure.

3. The adapter of claim 1, wherein the adapter includes a pip that projects lengthwise and rearward of the flange in order to provide additional strength to the flange and locate on a reveal fin of the window frame.

4. A window assembly with a window frame and the adapter, as claimed in any one of claims 1 to 3, fitted to the frame.

5. The window assembly of claim 4, wherein one or more adapters are fitted around the frame, to a head, sill and jambs of the frame, to provide a substantially continuous waterproof barrier around the window frame. C :WPorbt CC\CAB\4914317_I DOC.7/2/2013 - 14

6. A window assembly with a window frame and one or more adapters fitted around the frame prior to installation in a building structure, to provide a substantially continuous waterproof barrier around the window frame, wherein the or each adapter includes a main body to sit against the frame, an integrally formed connector to lock the adapter onto the frame and a flange to project laterally of the frame at a location spaced from an outer peripheral section of the frame, so as to extend between an underlying wall structure and cladding applied over the wall structure, the flange and body presenting a waterproof barrier around the frame.

7. A method of manufacturing a pre-fabricated window assembly including forming a window frame and securing one or more adapters to the frame prior to delivery to a building site where the window assembly is fitted into a building structure, wherein the or each adapter includes a main body to sit against the frame, an integrally formed connector to lock the adapter onto the frame and a flange to project laterally of the frame at a location spaced from an outer peripheral section of the frame, so as to extend between an underlying wall structure and cladding applied over the wall structure, the flange and body presenting a waterproof barrier around the frame, wherein the connector includes two parallel legs that snap fit over a corresponding connecting finger of the window frame and wherein an outer one of the legs extends over and covers the connecting finger of the window frame to form an outer face of the window frame so that the adapter presents an aesthetically seamless fit with the window frame.

8. A building including a building structure with a window assembly, as claimed in claim 6, fitted into the structure whereby the flange of the or each adapter sits adjacent the building structure and between the building structure and cladding applied over the building structure. C W4RPonbIDCC\CABW9143 171 DOC.7A2/2013 - 15

9. The building of claim 8, further including a thermal insulation membrane arranged over the building structure, wherein the membrane is bonded directly to the or each flange in order to provide a weatherproof seal between the membrane and the or each adapter.

10. A method of forming the building of claim 8, including: fitting a prefabricated window assembly, as claimed in claim 6, into the building structure; covering the building structure with a waterproof membrane and attaching the membrane to the barrier provided around the window assembly; and fitting cladding over the building structure, barrier and membrane.

11. An adapter, substantially as described with reference to the drawings and/or examples.

12. A window assembly, substantially as described with reference to the drawings and/or examples.

13. A method of manufacturing a prefabricated window assembly, substantially as described with reference to the drawings and/or examples.

14. A building, substantially as described with reference to the drawings and/or examples.

15. A method of forming a building, substantially as described with reference to the drawings and/or examples.