AU738498B2

AU738498B2 - Building elements

Info

Publication number: AU738498B2
Application number: AU97296/98A
Authority: AU
Inventors: Robert Andrew Allen; Leonard Mckeown; Colin Sharpels
Original assignee: James Hardie Research Pty Ltd
Current assignee: Trend Windows and Doors Pty Ltd
Priority date: 1997-12-19
Filing date: 1998-10-21
Publication date: 2001-09-20
Anticipated expiration: 2018-10-21
Also published as: AU9729698A

Description

0 PCT/AU9&/00875 Received 31 May 1999 -1- TITLE: "BUILDING ELEMENTS" FIELD OF THE INVENTION The present invention relates to an elongate joining or edging element for securing to at least one member formed from a partially resiliently deformable material such as timber, and in the preferred application to a composite frame element including such a joining or edging element.

BACKGROUND OF THE INVENTION The invention has been developed primarily for use in relation to timber door and window frames and will be described predominantly with reference to this application.

However, it will be appreciated that the invention is not limited to this particular use and that it can readily be used in other joining or edging applications using other materials or combinations of materials.

Timber window and door frame elements, such as door jambs, often require a relatively complex cross-sectional profile. Conventionally, this profile has been formed by moulding a single length of milled rectangular timber stock into the required shape.

Unfortunately, this method has a low yield, as it is an inherently inefficient use of materials due to the amount of material lost through the moulding process. Timber, by its nature, is also difficult to accurately machine to close tolerances and, furthermore, is prone to warpage making the production of effective sealing surfaces difficult to achieve.

In an effort to avoid this waste of materials, it has been known to laminate or otherwise connect a number of separate simple timber components together, optionally using locating dowels to thereby form the more complex frame element. This is a very time consuming and labour intensive batch procedure. It is also difficult to prevent AMENDED SHEET (Article 34) (IPEA/AU) SV PCT/AU98/00875 Received 31 May 1999 -2rainwater from penetrating the elements along the joins and glue lines if they are not glued correctly. As such, this technique is generally capital intensive and requires considerable skill and expertise.

In this regard, the deflection loading characteristics, rigidity and "straightness" of a window or door frame assembly, fundamentally influence its ability to provide an effective seal against the corresponding door or window sash. Accordingly, whilst the sealing abilities of internal doors or windows are often not crucial, the waterproofing requirements of external doors and windows requires that the frame assemblies adhere to strict manufacturing tolerances and deflection loading limitations.

Additionally, use of such lamination techniques to produce complex cross-section members complicates the mechanisation of window making processes.

It is an object of the present invention in its broadest form to provide an elongate joining or edging element that can overcome or substantially ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative thereto.

The present invention, in at least one of it's preferred forms, provides an improved composite frame element and method of making that element which overcomes or substantially ameliorates one or more of the disadvantages of the prior art, or at least offers a useful alternative thereto.

DISCLOSURE OF THE INVENTION According to a first aspect of the invention there is provided an elongate joining or edging element for securing to a member formed from an at least partially resiliently deformable material such as timber, said element having: a generally planar surface, AMENDED SHEET (Article 34) (IPEA/AU) W W PCT/AU98/00875 Received 31 May 1999 -3one substantially "U-shaped" cavity formed by two opposed first side walls extending outwardly from said planar surface, said cavity including a first tongue section intermediate and parallel to the side walls and extending outwardly from said planar surface to a point beyond at least one of said side walls, said side walls and tongue section being configured to frictionally and/or physically interact by means of a press fit with corresponding parallel slots and/or edge surfaces formed in a connecting surface of said resilient member so as to secure the element thereto.

In a preferred form a surface of the tongue and/or a surface of one or both of the side walls opposite the tongue includes thereon engaging formations to physically interact with the material of the resilient member. More preferably, a surface of the tongue and/or the surface of one or both of the side walls is tapered so as to urge the material of the resilient member towards securing interaction with said engaging formations.

According to a second aspect of the invention there is provided a composite frame element including an elongate joining element according to the first aspect and one or more elongate, generally planar building members suitably adapted for press fitting engagement with said joining element.

Preferably the joining element is specifically configured for use in frames for building construction and optionally can include retaining formations adapted to captively retain a cladding panel inserted therein. More preferably one or more external surfaces of the joining element remain exposed after the securing of.said building elements thereto, thereby providing a substantially straight abutment surface for a complementary AMENDED SHEET (Article 34) (IPEA/AU) 0 PCT/AU98/00875 Received 31 May 1999 -4construction component. Even more preferably, the frame element is configured for a window or door application in which the construction component is a window sash or door.

A particularly preferred form of the first aspect includes first and second mutually opposed, substantially U-shaped, cavities extending outwardly from two opposite planar surfaces formed on a central web, so as to define a substantially I-shaped section, the element further includes first and second directly opposed tongue sections extending outwardly from their respective cavities. In an alternative preferred form, the abutment surface extends past one end of the I-shaped section. In another highly preferred form the abutment surface extends past both ends of the I-shaped section. In yet another highly preferred form particularly suited for use in a jamb or head, one of the opposed side walls of one of the cavities is omitted. In another preferred form more than one tongue and corresponding side wall or walls may be included on any one planar surface.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a sectional part view of a window incorporating a conventional prior art component moulded from one solid timber element with attached trim; Figure 2 is a sectional part view of a window incorporating a composite frame element in the form of a jamb or head that includes a first embodiment joining element according to the present invention; Figure 3 is a sectional view of a first embodiment joining element according to the invention; AMENDED SHEET (Article 34) (IPEA/AU) PCT/AU98/00875 Received 31 May 1999 Figure 4 is a sectional view of a second embodiment joining element according to the invention; Figure 5 is a sectional part view of a composite mullion frame element that includes a second embodiment joining element according to the present invention; Figure 6 is a sectional part view of a window incorporating a composite frame element in the form of a mullion that includes a second embodiment joining element according to the present invention; Figure 7 is a sectional part view of a composite jamb frame element that includes a first embodiment joining element according to the present invention; Figure 8 is another sectional part view of a composite jamb frame element that includes a first embodiment joining element according to the present invention; Figure 9 is a sectional view of a first embodiment building member according to the present invention as used in Figure Figure 10 is a sectional view of a second embodiment building member according to the present invention as used in Figure 6.

Figure 11 is a sectional view of a third embodiment joining element according to the invention; Figure 12 is a sectional part view of a window incorporating a composite frame element in the form of a jamb or head that includes the third embodiment joining element shown in Figure 11.

PREFERRED EMBODIMENT OF THE INVENTION Figure 1 shows a sectional view of part of a prior art window 1' constructed using conventional techniques. The window 1' includes a frame member 2' in the form of a jamb AMENDED SHEET (Article 34) (IPEA/AU) SW PCT/AU98/00875 Received 31 May 1999 -6a glazing panel and a beading strip 4' to retain panel 3' within the window frame. As shown by broken lines 5' a substantial amount of timber is lost in the moulding process required to produce frame member 2' from the standard stock. Additionally, it can be seen that there is no barrier to the capillary action ingress of water from external side 6' of the frame to the internal side 7' of the frame.

Figure 2 shows an equivalent window 1 having a jamb 2 with a structure according to the present invention. The jamb includes internal and external jamb members 7 and 8, joined by an elongate joining element 9.

Joining element 9 is shown in further detail in Figure 3. The elongate element 9 defines, in cross-section, two substantially U-shaped cavities 11 and 12 which are attached to respective opposed planar surfaces 13 and 14 of a central core element in the form of web 15. Each cavity is in turn defined by opposed pairs of tapered side walls 18.

Extending outwardly from each of these cavities 11 and 12 are respective serrated tongues 19 and 20. Web 15 extends past the planar surfaces, at one end, to provide a barrier strip 21. In other embodiments the barrier strip includes means for attachment to a surrounding structure, hinge elements, means of attaching flexible weather seals and other components.

In the preferred forms the joining element 9 is constructed of extruded aluminium, but may in other embodiments be made from any one of the materials selected from the following group including: extruded or cast metal; folded or fabricated metal; extruded or cast polymeric material or pultruded reinforced polymeric materials.

In use, and returning to Figure 2, the internal and external members 7 and 8, which are provided with central slots 22 and tapered connecting edge surfaces 23, are pressed into engagement with respective sides of the joining element 9. In use, the tongue is introduced AMENDED SHEET (Article 34) (IPEA/AU) w W PCT/AU98/00875 Received 31 May 1999 -7into the central slot, thereby effecting a slight spreading of the member about the tongue.

As each jamb element 7 and 8 is forced further into cavities 11 and 12, tapered side walls 18 force the material surrounding slots 22 into engagement with the serrated tongues 19 and 20. With the application of compressive force by side walls 18 onto the correspondingly tapered edge surfaces 23 of element 9, the tendency of prior art joints employing tongues and slots, whereby the building element splits about the slot, is avoided. Additionally, because the strongest area of engagement is about the tongue, there is less chance of damage to the corners of the building elements by the application of stress to the joint.

It is clear that the amount of timber lost as waste during the milling process to produce members 7 and 8 is significantly less than that lost in the production of the prior artjamb. Moreover, ajamb similar to the prior art example has been produced using two smaller members 7 and 8. Thus, this jamb 2 can be more efficiently produced from standard sized stock. Additionally, supplies of larger section timber stock are becoming progressively more expensive than the smaller sections utilised in the present invention.

Another benefit of the present invention is that elements 7 and 8 may each be fabricated from different grades of timber, or various other materials. This allows the use of visually attractive materials for internal members 7 and weather resistant materials for external members 8.

In other embodiments (not shown) one or both of members 7 and 8 are constructed of PVC, metal or the like. Such elements would be constructed such that a separate engaging member is provided to interact with each tapered side wall 18 and each face of the joiner's tongue. As each element is forced into cavities 11 and 12 parts of adjacent engaging AMENDED SHEET (Article 34) (IPEA/AU) W PCT/AU98/00875 Received 31 May 1999 -8members are forced inwardly and thus engage the walls 18 and tongue by resilient response.

When the jamb is incorporated into a window, a glazing panel 3 may be abutted against one side of said barrier strip 21 and fixed into position by a beading strip 4.

In other embodiments, where the composite frame element is to be used in a frame for an openable door or window, the joining elements, shown in Figure 11, can include means 30 for retaining a resilient sealing strip 31 against which the window or door forms a substantially weathertight seal. These retaining means can be present around all or part of the frame. In embodiments where a horizontally hinged awning window is used (as shown in Figure 12) the joining element 35 can include an extension which has a curved hinge element 36 which, in combination with a corresponding element 37 on the sash, provides an integral hinge. Advantageously, such a hinge is also substantially weathertight. Alternative hinge formations may also be used.

In the embodiments illustrated the members to be joined are directly opposite each other, but it will be appreciated that in alternative forms they can be in planes parallel to but offset from one another or in planes perpendicular or at an angle to one another such as may be required in a frame element for a bay window for example. Also, if thick sectioned members are to be joined, then it may be appropriate to use ajoiner having two or more axially parallel U-shaped cavities, each with one or more respective tongues, all acting together to retain the inserted member. Alternatively, a single U-shaped cavity may include more than one tongue. In such examples it will not necessarily be the case that all cavities are coplanar. Indeed, it may be necessary that they are in a stepped relationship to each other to accommodate the configuration of the members to be joined.

AMENDED SHEET (Article 34) (IPEA/AU) PCT/AU98/00875 Received 31 May 1999 -9- Another advantage of such a structure according to the preferred form shown in Figure 2 is that the glazing panel 3 is directly seated against barrier strip 21 of the joining element 9. This affords a better seal, as a straighter edge adjacent the glazing is provided by the material of the joining element. Clearly this also applies to window sashes and doors sealing against the corresponding frame jamb portion provided by, or at least supported by, a joining element according to the present invention. Furthermore, it can be seen that barrier strip 21 provides a moisture barrier between external and internal elements 8 and 7, thus preventing any travel by capillary action of water between these external and internal elements.

In a further embodiment, particularly useful as a window jamb or head a U-shaped cavity is present on each of the opposed abutment surfaces as shown in either of the illustrated embodiments in Figures 3 or 4, except that the only barrier strip included extends towards the surrounding structure. This particular embodiment is different however in that one of the side walls 18 adjacent the interior of the jamb is omitted allowing the timber jamb member to extend over the top of the joining element. The benefit associated with this embodiment is that the appearance of the timber frame is not interrupted by the metal joining element.

In embodiments where the element only includes one U-shaped cavity and one associated tongue section the element is suitable for use as an edging element. An example of where such a section may be useful is providing a durable edge to a fascia or timber table or the like.

In other embodiments (not illustrated) the central web 15 is of hollow construction.

Such hollow cavities may be partially or completely filled with other elements, for example AMENDED SHEET (Article 34) (IPEA/AU) SPCT/AU98/00875 Received 31 May 1999 steel sections, to obtain increases in strength or rigidity. Alternatively the cavity may be used for the running of electrical wires or other services.

To achieve joining elements of greater complexity each element may include a number of separately formed sub-elements.

Figures 5, 6 and 7 show other frame structure embodiments possible using the invention. It will be noted that, in Figures 4 and 5, the central web 15 extends beyond both ends of said abutment surfaces to provide a barrier strip 21 at each end of the web.

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.

AMENDED SHEET (Article 34) (IPEA/AU)

Claims

2. An element according to claim 1 wherein said tongue section extends to a point beyond both of said side walls.
3. An element according to claim 1 or 2 wherein both of said side walls extend the same distance from said planar surface.
4. An element according to any one of the preceding claims wherein one or more surfaces of the tongue and/or one or more surfaces of one or both of said side walls opposite said tongue includes thereon engaging formations to physically interact with the material of the resilient member. An element according to any one of the preceding claims wherein a surface of the tongue and/or the surface of one of said side walls is tapered so as to urge the material of the resilient member toward securing interaction with one or another surface of said first Stongue or sidewalls. .AMENDED SHEET (Article 34) (IPEA/AU) W W PCT/AU98/00875 Received 31 May 1999 -12-
6. An element according to claim 5 wherein said tapered surface is opposite a surface including engaging formations.
7. An element according to any one of the preceding claims configured as a joiner wherein a first planar surface is formed on one side of a central core section and a second planar surface formed on another side of said core section, wherein said second surface of said core element has extending outwardly therefirom a second tongue section and at least one second side wall spaced therefrom.
8. An element according to claim 7 wherein the surfaces of said second tongue and/or second wall include one or more tapers and/or engaging formations.
9. An element according to claim 7 or claim 8 wherein said core section comprises a generally planar web section with first and second tongue formations extending outwardly from directly opposed first and second planar surfaces. An element according to any one of claims 7 to 9 wherein said opposed tongue formations and or one or more of said side walls are laterally offset from one another.
11. An element according to any one of claims 7 to 10 wherein said first and second planar surfaces are at an included angle of less than 1800 to each other.
12. An element according to any one of claims 7 to 11 wherein said core section is of a hollow construction.
13. An element according to claim 12 including a strengthening insert within said hollow core section.
14. An element according to any one of the preceding claims wherein said element is constructed of a plurality of sub-elements. An element according to any one of the preceding claims including more than one Stongue on any one planar surface. AMENDED SHEET (Article 34) (IPEA/AU) V PCT/AU98/00875 Received 31 May 1999 13-
16. An element according to claim 15 wherein each tongue on any one planar surface has at least one corresponding side wall.
17. An element according to any one of the preceding claims including additional means for attachment of said element to a surrounding structure.
18. An element according to any one of the preceding claims constructed from any one of the materials selected from the following group including: extruded or cast metal; folded or fabricated metal; extruded or cast polymeric material or pultruded reinforced polymeric materials.
19. A composite frame element including an elongate joining element according to any one of the preceding claims and one or more elongate, generally planar building members suitably adapted for press fitting engagement with said joining element. A frame element according to claim 19 specifically configured for use in frames for building construction wherein said joining element includes a retaining formation adapted to captively retain a cladding panel inserted therein.
21. A composite frame element according to claim 19 or claim 20 wherein one or more external surfaces of said joining element remain exposed after the securing of said building members thereto, thereby providing a substantially straight planar abutment surface for a complementary construction component.
22. A frame element according to claim 21 configured for a window or door application wherein said construction component is a window sash or door.
23. A frame element according to any one of claims 19 to 22 wherein said building members are made from timber.
24. A frame element according to any one of claims 19 to 22 wherein at least one of said Sbuilding members is made from PVC, metal or the like. AMENDED SHEET (Article 34) (IPEA/AU) -14- A frame element according to claim 24 wherein said building member includes a separate engaging member for engaging each of said side walls and each face of said tongue.
26. An elongate element according to claim 1 including first and second mutually opposed, substantially "U-shaped", cavities extending outwardly from two opposite abutment surfaces formed on a central web so as to define a substantially "I-shaped" section, said element further including first and second directly opposed tongue sections extending outwardly from their respective cavities.
27. An element according to claim 26 wherein said planar surface extends past one end of said "I-shaped" section to form a moisture barrier between two adjacent joined building members.
28. An element according to claim 26 wherein said abutment surface extends past both end of said "I-shaped" section to form a moisture barrier between two adjacent, joined building elements. 15 29. An element according to claim 26 where one of said opposed side walls of one of the cavities is omitted.
30. A composite frame element including one or more elongate joining elements according to any one of claims 26 to 29 and two or more generally planar building members suitably adapted for press fitting engagement with said joining elements.
31. An elongate joining or edging element for securing to a member formed from an at •least partially resiliently deformable material such as timber, substantially as herein described with reference to any one of the embodiments of the invention illustrated in the accompanying drawings. DATED this 12th day of January 2001 JAMES HARDIE RESEARCH PTY LIMITED Attorney: JOHN D. FORSTER Fellow Institute of Patent and Trade Mark Attorneys of Australia of BALDWIN SHELSTON WATERS