AU4240199A - Joinery construction - Google Patents

Description

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AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant/s: Actual Inventor/s: Address for Service: Invention Title: Details of Assoc. Provisior and Convention Applicatio Architectural Profiles Limited lan Paul Baines and Michael Frederick Glover BALDWIN SHELSTON WATERS MARGARET STREET SYDNEY NSW 2000 "CONDENSATION CONTROL IN JOINERY' nal in No's: New Zealand Patent Application No. 331231 filed 31 July 1998 and PP5753 filed 8 September, 1998.

The following statement is a full description of this invention, including the best method of performing it known to me/us:- File: 22600.00 ;i DO U- eeieo 2

INTRODUCTION

This invention relates to improvements in joinery construction and method of manufacture of joinery, and has particular applications to glazing and condensation control in joinery.

BACKGROUND TO THE INVENTION In the past, joinery has traditionally been constructed in a variety of elongate materials including timber, metal (particularly aluminium), and some plastics materials.

Construction of joiriery in one or other of the above-mentioned materials, or others, has resulted for reasons of convenience, economy and the like in the normally intended inner portions of the joinery being formed in a material common with that used on the outer or exterior exposed portions of the joinery.

An internationally growing trend of considerations of aesthetics, particularly the interior aesthetics of joinery is developing in importance, where customer demand has created a market for so called "composite" joinery is formed from a mixture of materials, often taking the best of the inherent advantages of each material and 25 reducing, if not eliminating the disadvantages of such materials in the resultant finished article.

As an example, timber, whilst often regarded as having highly desirable aesthetic properties, particularly on the interior of a building, carries with it the disadvantages of manufacturing costs, high maintenance and a lack of weatherliness. Further, aluminium, whilst often able to technically provide joinery performance aspects desired and meet cost criteria, is often regarded by customers to lack the desired beneficial aesthetic properties. Aluminium joinery is also often 35 associated with problems of heat conduction and associated heating and condensation control difficulties, particularly in colder climates.

Plastics, for example PVC and UPVC manufactured joinery, whilst providing inherent insulation and cost advantages, is often associated with compromised mechanical properties, particularly in tortional rigidity and generally strength, together with other perceived durability and aesthetic disadvantages.

Composite joinery construction also has in many instances been found to also be compromised, for example in the-cost of manufacture and in performance where condensation on and between interior exposed glazing, metal and timber componentry of the joinery can lead to significant disadvantages. These disadvantages have been at least to some extent identified and addressed in our co-pending Australian patent application number 83099/98.

Whilst condensation and deterioration of the joinery components as a result of exposure to moisture and dampness, together with staining as a result of mould and the like has been a problem in composite joinery, the addressing of removal of condensation on the interior of a building, particularly on joinery componentry has been a significant problem, particularly in colder or more humid climates. Attempts have been made to address condensation issues in a variety of ways; some have included the use 25 of specialist expensive glazing panels including multiple glazing sheets which increase the ability of the joinery to create a high thermal gradient between the inner and outer surfaces of the glazing in use, however exposed surrounding conductive material can still create condensation problems.

Where multiple glazing is utilised, often special joinery and a variety of joinery components are necessary to enable the multiple glazing, this leads to significant manufacturing cost in terms of stock holding, varieties of extrusions, extrusion shapes and the like.

Furthermore, often it is difficult for the joinery manufacturer to present to customers joinery having a common appearance where, for example, some joinery is multiply glazed and others are single glazed.

This difference in appearance, the presence of often exposed joinery components in comparative single glazed joinery and the often significant added cost has been found to discourages customers from S potential usage where it might be appropriate, particularly in temperate climates where the need for multiple glazing (in the absence of an additional noise control requirement) is arguably "essential" only on the "cold" sides of the building not generally exposed to direct sunlight.

It is an object of this invention to come some way in overcoming the above-mentioned problems or at least provide the public with a useful choice.

OBJECTS OF THE INVENTION Other objects of this invention will become apparent from the following description. Modifications are envisaged and may be incorporated without departing from the scope or spirit of the invention.

0 BROAD DESCRIPTION OF THE INVENTION According to one aspect of this invention there is provided a 25 joinery construction adapted for mounting panels selected from a predetermined range of thicknesses, said joinery construction incorporating at least one frame portion having a recess into which an edge portion of a selected panel is positionable, said recess having spaced apart abutment portions between which said panel edge is 30 engageable in said recess, said joinery construction including a separate elongate infill element engageable in said recess between an inner surface of said panel and the opposed abutment in said recess to infill said recess between said panel and the opposing abutment and provide a secondary abutment in said recess for positioning said panel, when the panel positioned in said recess is thinner than a maximum panel thickness in the range.

According to a further aspect of this invention, the infill element is formed as an elongate member in sufficiently rigid material to form a secondary abutment for said recess.

According to a further aspect of this invention, the infill element is formed in a material of a lower thermal conductivity than remaining portions of said frame and/or a glazing panel forming an outer exposed surface of said joinery construction.

According to a still further aspect of the invention, said infill element when positioned adjacent a lower edge of said glazing panel is provided with an upwardly open recess therein for receiving liquid which may run from remaining portions of said joinery construction thereabove.

According to a further aspect of the Invention, the infill element is positionable in the recess between an inner surface of said glazing panel and an abutment surface of said glazing recess to control the position of an outer surface of said glazing panel in a substantially predetermined position, notwithstanding a thickness of said glazing panel used in said joinery construction.

According to a further aspect of this invention there is provided 25 a method of constructing joinery including the steps of, forming joinery frame elements to have a recess capable of accommodating an edge *'..portion of a panel selected from a predetermined range of panel thicknesses forming at least one elongate infill element and engaging said infill element in said recess between an abutment face of the 30 recess and an inner face of said panel to position an outer face of said ~panel in a substantially predetermined position relative to remaining portions of said joinery, notwithstanding the thickness of said panel.

According to a further aspect of this invention the method includes the step of forming said infill element to have a condensation groove therein and placing said infill at least in a lower portion of said recess for said condensation groove to receive any liquid running from at least said panel.

According to a further aspect of this invention the infill element includes at least one port which is positioned to enable movement of fluid through said joinery construction from an outer side, to said inner side and vice versa.

According to a further aspect of-this invention the port incorporates control means to control movement of said fluid there through.

Others aspects of this Invention should be considered in all its novel aspects will become apparent from the following description.

INTERPRETATION

Throughout this specification, references are made to "inner" and "outer", and "exterior" and "interior" and words of a similar orientational concept with reference to buildings and joinery. These references are to be taken logically as referring to the outer portions or inner portions with reference to what is generally regarded as the exterior of the building assuming the joinery is intended for placement :i 25 close to the building from the exterior environment or the interior of the building. Further orientational references such as "upwardly" and "downwardly", are also to be logically taken In an orientation relevant to the normal usage of the element/componentry or article with which use is normally contemplated.

DESCRIPTION OF PREFERRED EMBODIMENT The preferred form of the invention will now be described with reference to the accompanying drawings in which: Figure 1: Is a diagrammatic typical joinery construction crosssection through a sill for fixed multiple glazing; in this case double glazing in a frame member; the sill board or jamb liner is partially shown.

Figure 2: Is a similar view to that described with reference to Figure 1, except where the joinery construction accommodates single glazing.

Figure 3: Is an exploded perspective partial view of a typical corner joint assembly between a sill and joints In the single glazed form according to Figure 2 showing a drainage arrangement for condensation.

Figure 4: Is a similar corner perspective partial view in non exploded form showing an alternative drainage arrangement for condensation.

Whilst the preferred embodiment of the invention is described with reference to Figures 1 and 2, and in relation to, so called, composite joinery, the invention is not limited thereto and is applicable to all forms of joinery where varying thicknesses of glazing and glazing panels for the joinery is intended.

The preferred form of the invention is also described by way of example with reference to a typical joinery frame construction incorporating a sill, two spaced apart parallel jambs and a head to provide a substantially rectangular closure for a building opening, 30 substantially according to known techniques. The invention is, 00 ~however, not limited to this configuration of joinery and is applicable to almost all joinery forms contemplatable where multiple thickness glazing is normally possible.

Except as described hereinafter, should be contemplated that in the main, references to the cross-sectional configuration of the sill also apply to remaining perimeter elements of the frame in accordance with normal joinery manufacture techniques.

Referring now to the drawings and in particular Figures 1 and 2 the joinery construction as indicated by arrow 1 preferably includes a frame 2, in this form a sill 2 having a frame flange 3 is adapted to overlay adjacent portions of the building outer surface adjacent an opening with which the joinery construction and is engageable in use, with remaining portions of the frame 2 extending inwardly of the building to position a jamb liner 4, preferably formed in timber material and mounted on an inner surface of the frame 2 to trim an inner portion of the building opening in the substantially known manner and to facilitate engagement of the joinery constructions within the building opening.

The frame 2 in this form, but not essentially provides a glazing recess generally indicated by arrow 5 which in the preferred form of the invention (although not essentially) is openable to the exterior of the joinery construction by removal of a detachable glazing bead 6 which inter-engages with adjacent portions of the glazing recess 5 and facilitates the insertion, engagement and replacement of a glazing 25 panel, in Figure 1 shown as a multiple (double) glazed "cavity" panel of substantially known construction, or alternatively in Figure 2 as a single sheet of glass for "single glazing".

It should be appreciated that whilst the invention is described 30 with reference to unframed glazing panel 7 assemblies, in alternative arrangements, the glazing recess 5 can be adapted to accommodate a framed glazing panel 7, for example a glazed sash or other panel, and even an unglazed solid panel however in such circumstances it may be necessary to dispense with the glazing bar 6 and use such glazing bar in the sash assembly.

In this preferred form of the invention, the joinery construction frame portions 2 are formed in extruded metal, preferably aluminium, although this is not essential to the invention.

The glazing recess 5 in this form of the invention is adapted to receive a range of predetermined glazing panel thicknesses and provides a pair of opposingly arranged abutment portions 8, being an inner abutment 8a and an outer abutment 8b, a spacing between the abutment portions 8 being a dimension plus a working tolerance, for example for compressable sealing means 9 and 10 to enable accommodation of a contemplated thickest glazing panel 7 therebetween and securement and sealing of the glazing panel 7 in said glazing recess 5 via traditional resilient glazing wedges 9 and sealing strip 10 and the like.

Referring now specifically to Figure 2, where the invention is adapted for a single glazing panel 7 or a glazing panel 7 of a predetermined thickness less than the glazing panel 7 described with reference to Figure 1, an infill member 20 is provided.

In the preferred form of the invention, the infill member 20 is provided in a material having a thermal conductivity less than the thermal conductivity of remaining portions of the joinery exposed on 25 the outer surface thereof and preferably specifically including the glazing 7 and frame 2. The infill 20 is formed in a substantially rigid plastics material, such as PVC or UPVC and is preferably coloured to match with timber or other portions on the inner side of the joinery, however this is not essential.

The infill member 20 is provided as an elongate extrusion of a variety of width dimensions to suit glazing used, arranged to position in the glazing recess 5 inwardly of an inner surface 7a of the glazing panel 7 and take up a spacing between the abutment 8a of the glazing recess and the inner surface 7a of the glazing panel 7, around the length of the glazing recess 5 provided by the frame 2, that is to say, also in the frame portions also forming the jambs and head, so that when mounted the glazing panel 7 a front face 7b of the glazing panel 7 is positioned in a substantially similar position to its position when a multiple glazed panel 7 is utilised as will be seen by a comparison of Figures 1 and 2. It will be appreciated that the infill member 20 is sufficiently rigid to produce a secondary abutment for said glazing panel 7 in the recess In the preferred form of the Invention, a range of varying thickness Insert portions 20 are provided, preferably, although not exclusively, to enable the joinery 1 to accommodate glazing panel 7 thicknesses selected from a range of the minimum thickness contemplated single glazing format, through to thicker glazing panel 7, even including some relatively thin multiple, and preferably double glazing unit 7, incorporating an insulating cavity there between. In the preferred form of the invention, however, preferably with multiple glazing, it is intended that the insert portion 20 will be removed from the recess 5, and the recess 5 being of a dimension which will accommodate the thickest contemplated multiple glazed, for example, double or triple glazing panel 7 for use. Typically, the glazing recess is adapted to receive glazing panel 7 in the range of 2mm, to 13mm thickness, however these dimensions are in no way limiting.

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25 In this form of the invention the insert portion 20 is preferably upwardly grooved at 21 to provide a receptacle in the sill area of the joinery for receiving and holding liquid, such as condensation and the like running from the interior face 7a of the glazing panel 7, to prevent the liquid running where unwanted, for example on to a timber facing the inner surfaces of the joinery construction 1, or onto walls or adjacent curtains (not shown). In the preferred form, and with reference to Figure 4, preferably, the insert portion 20 extends along the full length of the sill element 2 and abuts with end portions 20a of other insert portions 20 engaged in the jambs, such that a small opening 25 is provided by the grooves of the jamb inserts 20 facing side of the sill insert 21 at each end of the sill 2 whereby the liquid runoff can pass conveniently into the glazing recess 5 and drain outwardly therefrom to the exterior of the joinery 1 via a weep hole 26 or other drains 11 in the joinery elements.

With reference to Figures 3, whilst not essential to the invention, it is alternatively contemplated that the construction of this invention may also include a valving mechanism 27 constructed substantially as described in our co-pending Australian patent application number 26152/97. In this form but not essentially the valving mechanism 27 may be positioned under end portions of the Insert portions 20 of the jambs, to hide, substantially, the valve mechanism 27 from view.

In this form of the invention, the insert portion 20 is additionally preferably provided with an appropriately reduced opening recess 23 within which resilient sealing means 10 may be engaged so as to provide a seal between the inner surface 7a of the glazing panel 7 and remaining portions of the joinery. Further, a flange 22 on an opposing side of the insert 20 is preferably arranged with a cover portion 24 arranged to extend inwardly of the joinery construction 1 to slightly overlap an upper surface of an adjacent timber facing for the frame, so as to substantially hide the metal portions of the frame 2 from view on 25 an interior of said joinery construction land at least thermally insulate those portions from the building interior in use.

C *6 Preferably elongate engagement portions 25 are positioned on the insert portion 20 in such a position as to "snap" engage In a 30 reduced opening recess 12 on the abutment 8a normally provided for engaging the sealing means 10 in the form of the invention shown in Figure 1. This engagement facilitates the securement of the insert in position, whereafter it is not simply dislodged. The base 26 of the insert preferably impinges against an adjacent wall 13 of the glazing 0 recess 5 to thus securely position the insert portion 20 between the inner surface 7a of the glazing panel 7 and the abutment 8a.

12 It will be appreciated that the need for condensation control is largely unrequired with the multiple glazing configuration of Figure 1, whereas, in the single glazed configuration, condensation is likely to be a significant difficulty, and such condensation capture and control Is provided in a manner which is both effective and economic. Whilst additionally enhancing the thermal insulative nature of the frame and exposure of the frame portions are likely to lead to condensation.

Further, the joinery construction 1 in either the multiple glazed or single glazed configuration presents a similar appearance on the exterior of the building and furthermore, the insert 20, enhances the aesthetics of the joinery when used in a single glazed configuration, especially in conjunction with multiple glazed similar joinery in close proximity.

Whilst the invention has been described with reference to one form, it is to be appreciated that modifications and developments may be incorporated without departing from the scope or spirit of the invention, as defined in the appended claims.

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Claims (21)

1. A joinery construction adapted for mounting panels selected from a predetermined range of thicknesses, said joinery construction incorporating at least one frame portion having a recess into which an edge portion of a selected panel is positionable, said recess having spaced apart abutment portions between which said panel edge is engageable in said recess, said joinery construction including a separate elongate infill element engageable in said recess between an inner surface of said panel and the opposed abutment in said recess to infill said recess between said panel and the opposing abutment and provide a secondary abutment in said recess for positioning said panel, when the panel positioned in said recess is thinner than a maximum panel thickness in the range.

2. A joinery construction as claimed in Claim 1 wherein the infill element is formed as an elongate member in sufficiently rigid material to form the secondary abutment for said recess.

3. A joinery construction as claimed in any one of the preceding claims wherein the infill element is formed in a material of lower thermal conductivity than remaining portions of said frame 25 and/or panel in communication for heat conduction with outer exposed portions of said joinery construction. *o

4. A joinery construction as claimed in Claim 3 wherein the infill element is formed in an extruded plastics material.

A joinery construction as claimed in any one of the preceding claims wherein the panel is a transparent or translucent panel including a glass panel. 35

6. A joinery construction as claimed in any one of the preceding claims wherein at least one port is provided as an opening defined by non correspondingly shaped abuting end portions of separate infill elements co-operating in said frame recess, in a sill region of said joinery construction.

7. A joinery construction as claimed in any one of the preceding claims wherein the infill element, when positioned adjacent a lower edge of said panel is provided with an upwardly open recess therein for receiving liquid which may run from remaining portions of said joinery construction thereabove.

8. A joinery construction as claimed in any one of the preceding claims wherein the infill element includes at least one port therethrough which is positioned to enable movement of fluid from portions of said joinery construction thereabove, to an exterior of said joinery construction.

9. A joinery construction as claimed in Claim 8 wherein the at least one port is positioned to enable two way movement of fluid through said joinery construction from an outer side to an inner side thereof, and/or vice versa.

10. A joinery construction as claimed in Claim 8 or Claim 9 wherein the port incorporates a control means to control the movement 25 of fluid therethrough.

11. A method of constructing joinery including the steps of, forming joinery frame elements to have a recess capable of accommodating an edge portion of a panel selected from a predetermined range of panel thicknesses forming at least one elongate infill element and engaging said infill element in said recess between an abutment face of the recess and an inner face of said panel to position an outer face of said panel in a substantially predetermined position relative to remaining 35 portions of said joinery, notwithstanding the thickness of said panel.

12. A method of constructing joinery as claimed in Claim 11 including the step of forming said Infill element in a material sufficiently rigid to provide a secondary abutment face with which said panel may abut In the completed joinery construction.

13. A method as claimed in Claim 11 or Claim 12 including the step of selectively installing panels chosen from a range of predetermined thickness and engaging a predetermined thickness infill element into said recess to match the thickness of said selected panel to position an outer face of said panel in a predetermined position while facilitating installation of thicker glazing on variation or removal of said insert.

14. A method of constructing joinery as claimed in Claim 7 or Claim 8 including the step of substituting a thin panel each with a thicker panel each selected from the predetermined range and adjusting said recess to enable accommodation of said thicker panel by removal or substitution of said infill element from said recess.

15. A method as claimed in Claim 14 Including the step of forming at least said thicker panel as a glazing panel which consists of 25 two or more sheets of glazing arranged to define at least one cavity within said panel.

16. An insert in the joinery construction as claimed in any one of Claims 1 to 6.

17. An insert used according to methods as claimed in any one of Claims 11 to 13.

18. A joinery frame element incorporating a glazing recess, adapted 35 to receive a panel therein with an outer surface of said panel abutting an outer abutment, an Inner abutment provided to oppose an inner surface of said panel and an insert to provide a secondary abutment face of at least one dimension which co- operates in the recess and with the panel thickness to provide a secondary abutment face for said panel whilst maintaining an outer face of said panel against said outer abutment face.

19. A joinery construction as hereinbefore described with reference to Figures 1 and 2 of the accompanying drawings.

A joinery construction as hereinbefore described with reference to Figures 3 and 4 of the accompanying drawings.

21. A method of constructing joinery as hereinbefore described with reference to the accompanying drawings. DATED this 30th day of July, 1999 ARCHITECTURAL PROFILES LIMITED Atto ey: RUSSELL J DAVIES allow Ingtitute of Patent Attorneys of Australia of BALDWIN SHELSTON WATERS