AU784090B2 - Window and door framing arrangements - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Applicant(s): PERU PERUMAL GEORGE MADFOUNI Invention Title: WINDOW AND DOOR FRAMING ARRANGEMENTS The following statement is a full description of this invention, including the best method of performing it known to me/us: 2 WINDOW AND DOOR FRAMING ARRANGEMENTS The present invention relates to a system applicable to the design and installation of door and window arrangements in buildings and extends to a new approach to forming the building with defined openings.

Traditional building systems, particularly for dwellings, present many difficulties because of the trades employed and the consequential lack of a design approach which .:00 simplifies, as far as possible, the installation of frames, and doors and windows to be installed within such frames in a building. One approach is for a temporary timber frame of the correct dimensions to be fabricated *ibe 15 and used as a template to define an opening around which a building is constructed. The temporary frame is then removed and the window contractor then attaches the window or door construction to the opening, utilising flashing which hopefully has been correctly installed in the wall S" 20 and floor construction phase and hopefully which has not been damaged. Another alternative is for example, a wall from brickwork to be laid accurately to define an opening.

i In such circumstances there is a distinct risk that windows or doors and their frames will not readily fit accurately with appropriate weather sealing. Furthermore, with this approach it is imperative that the tradesmen are very accurate.

Another approach is to build in a window, complete with its frame, during building operations. However, with the involvement of wet trades such as bricklayers, plasterers and painters there is a frequent problem with damage to the window in terms of its frame and/or glass work. At the very least it requires careful cleaning at the end of the process. In the case of sliding doors, the tracks provided for the doors frequently become damaged by sand, cement and wheelbarrows, and expensive repair work may be needed Speci/400-499/449-499/45205 3at the end of the building process.

In summary, difficulties arise from the integration of different trades and different components and the builder has the problem of rectifying these problems. In general substantial allowance is needed in the pricing of building work for such rectification, including the possibility of doors or windows having to be replaced due to damage and/or glazing to be replaced at significant expense.

Furthermore, disputes as to responsibility for defects can be a significant economic and administrative issue.

The present invention manifests itself in various aspects including novel extrusions for frames and a new approach 15 to a framing system and method of building which is aimed at providing an elegant, new and effective design approach which, at least in preferred embodiments, provides major advantages, as will be discussed below. The present invention is particularly beneficial when directed to 20 residential construction but is not necessarily so limited and will have the potential for value in commercial and industrial construction projects.

A key aspect of the present invention is the concept of utilising a suitable extrusion, described in more detail below, to form a frame which is utilised as part of the framing for a door or window opening in the structure, the frame defining an opening in the building structure and around which the building structure is formed with the frame being integrated into the structure, the frame having functionality so that a desirable appearance is achieved but with features which facilitate weather proof inter-engagement with the building structure and a form which lends itself to protection against damage during the building process but which is a final component of the installed door or window system at the end of the building operations.

Speci/400-499/449-499/45205 -4- In one aspect the present invention consists in an extrusion for forming a frame defining an opening in a building structure and having: a tubular body portion; a first side face having at least one fin extending away therefrom for engaging with an exterior wall element to define the relative location of the wall element and to provide weather sealing; and a second opposite side face adapted to receive and have attached thereto a window or door peripheral element •go• and having a shoulder to define a location for an edge of the peripheral element and provide a weather seal at that location.

S The extrusion is preferably formed in aluminium with a selected surface coating temporarily protected by a removable protection layer or coating and of generally rectangular tubular cross sectional form with two parallel 20 integrally formed spaced fins to define a wall cavity.

Typically the overall dimensions of the extrusion are around 150 mm x 50 mm.

The extrusion lends itself to mitre joints and accordingly a rectangular framework for defining an opening can readily be formed using suitable L-shape corner brackets which penetrate into the adjacent extrusion portions.

Advantageously, the shoulder is provided by a tubular extension portion intended to be on the inside of the building structure. With advantage this tubular extension can provide an undercut recess to confront the peripheral element of the door or window to provide anchorage for a weather sealing strip.

Furthermore, the tubular extension has a rear wall Speci/400-499/449-499/45205 parallel to the first side face but set back therefrom to a plane between the first side face and second opposite side face so as to provide a rebate from the inner wall of the structure for accommodating a finish such as a rendered finish or to accommodate plaster board. Thus a neat clean finish can be advantageously provided.

On the edge of the extrusion adapted to be the outer edge, preferably a second tubular portion is provided with a rear wall also in a plane generally between the first side face and the second opposite face to provide a rebate as either a shadow line or as a recess to also accommodate a surface finish such as render.

In another aspect, the invention extends to a polygonal frame such as rectangular for defining an opening for a door or window in a structure and comprising four lengths of extrusion in any one of the forms described above, formed with mitre jobs into a rectangular framework and S 20 provided with a protective layer, such as a plastic film wrap, which can be left on the product until building work has completed and the protected layer is then removed at the time of installation of the door or window component.

25 Alternatively, the invention may be defined as a method of building using a framework having a multiplicity of extruded frame elements for defining an opening in a building structure and forming a permanent part of the .structure to be built around the framework, the frame elements providing means for locating and connection to the structure with a weather seal, and means for locating and forming a weather seal within the zone defined within the framework for a peripheral frame element of a door or window unit.

In a further aspect, the invention consists in a method of building a structure having an opening in a wall for a Speci/400-499/449-499/45205 6 door or window, the method including taking a rectangular frame in any one of the forms defined above and installing the frame in a vertical plane on a base structure formed in the building structure, constructing walls around and up to the opening with engagement of the wall structure with the rectangular frame with an inner face of the outer wall engaging a corresponding fin on the extrusion, the frame including spacings means to define a cavity in the wall and to provide an abutment for an inner wall structure and after completion of wall construction and preferably after completion of surface finishing around the framework, installing a door or window peripheral frame to the framework.

:°ooo• 15 For illustrative purposes only, an embodiment of the invention will now be described with reference to the :accompanying drawings of which: Figure 1 is a cross sectional view of a preferred aluminium extrusion for implementing the invention; 20 Figure 2 is a cross sectional view in a vertical plane through a corner joint formed by mitre cutting and engagement of two of the extrusions of Figure 1; Figure 3 is a plan view of a gasket for use with the extrusion; Figure 4 is a side view of the gasket of Figure 3; Figure 5 is a cross sectional view of an accessory for use in the system and of the nature of a top hatshaped lintel; Figure 6 is an isometric view illustrating installation of the extrusion as part of a rectangular frame for a window which is shown in the installed position; Figure 7 illustrates a typical installation in cavity brickwork; Figure 8 illustrates typical installation with a balcony threshold and cavity brickwork; and Figure 9 illustrates an alternative installation with Speci/400-499/449-499/45205 7 integration of the framework into a pre-cast concrete structure.

Figure 1 illustrates an extrusion 10 having a generally rectangular form and typically of around 150 mm x 30 mm with a wall thickness of around 1.8 mm. The extrusion has a main body portion 11 having transverse internal walls 12 extending between a first rear face wall 13 and a second front face wall 14. Lateral walls 15 and 16 are provided thereby defining square cross sectional shape tubular cavities 17 each adapted to receive corner stakes 18 performing a mitre joint as shown in Figure 2.

:°oooo The extrusion wall 11 also has an outer end wall 19 with 15 its front face provided by the front wall 14 and a rear wall 20 which has an under-cut recess 21 near the outer wall 19 whereby an outer rectangular tubular cavity 22 is defined, the free outer portion of the lateral wall providing a shoulder and the structure thereby providing a 20 rebate for accommodating a finish such as a rendered surface as discussed further below. The inner side of the extrusion 10 has an inner tubular cavity 23 defined by a wall providing a shoulder 24 and accommodating an undercut recess for a sealant material and an inner end wall with a rear also providing an under-cut recess 27 and position also to provide a rebate for accommodating interior finish materials if required.

Integrally formed fins further extend from the rear face 13 but in the preferred embodiment reduced thickness is provided adjacent to the rear face so that the fin can be snapped off if so required for a particular installation.

Normally the fins define a cavity.

Being extruded aluminium permits the lengths of extrusions to be finished e.g. by anodising or powder coating, and then wrapped with heavy duty shrink wrap plastic for Speci/400-499/449-499/45205 8 protection. The wrapping is only removed after final completion of all building work and prior to installation of doors or windows.

Referring now to Figure 2, the L-shaped corner stake 18 is a plastic or aluminium moulded product, square cross sectional shaped and arranged to fit in the square tubular portion 17. The stakes typically have legs which are approximately 100 mm long and are adapted to be secured in position by fixing screws 31 from the rear face.

To provide a weather seal, the mitre joints preferably use a shaped gasket 32 as shown in Figures 3 and 4, the gasket having apertures 33 for accommodating the corner stakes.

e Figure 5 shows a lintel 34 of top hat-shape and adapted to be installed above a horizontal top part of a framework formed from the extrusion, as illustrated in Figures 7 and 8. This lintel has been designed to eliminate the need for 20 flashing over the top of brick openings and for that purpose has an angled top wall 35 to be installed inclined towards the outside so as to cause any moisture drips to move to the outside of the structure. The lintel has horizontal flanges 36 which are adapted to support the skins of the brickwork.

Figure 6 shows a vertical frame 37 of the extrusion in accordance with Figure 1 used with a cavity brick wall with the fins 30 being used to engage the respective inner faces of the brick work and by virtue of the mortaring process to engage therewith thereby obviating the need for flashing or brick ties and providing a weather seal.

Figure 6 illustrates the use of render 39 and 40 applied into the respective rebates behind the tubular portions 23 and 22 whereby a neat, clean and effective arrangement is provided with precise vertical straight lines at the junction, a result very difficult to achieve with SpeciI400-499/449-499/45205 9 conventional building methods and installations.

Figure 6 shows a window frame having a stile 42 of a suitable aluminium extrusion in which a glass sheet 43 is installed, the stile being in abutment with the outer face 14 of the extrusion 11 and in abutment with sealant provided in the under-cut shoulder 24 to provide weather sealing. It is intended that the stiles 42 are fixed to the extrusion 11 permanently by screws.

The system according to the present invention facilitates accurate factory production and by virtue of the configuration of the extrusion with the four pairs of plastic stakes and the gasket performing sealed accurate 15 mitre joints, stability in the main framework is provided yet it can be readily protected during building S.operations.

Figure 7 illustrates use of the framework in a brick 20 cavity wall in a vertical sectional view and for installing a window. An upper section 70 and a lower horizontal section 71 are provided. The drawing shows the :completed structure with double skin brick work having the cavity defined by the fins 30 below the window and during construction the brick sill 73 is simply placed in position as construction proceeds, a great advantage over conventional building methods. Figure 7 shows an outside layer of render 74 and an inner layer of render 75 applied to the brick work as a finishing trade and extending into the rebate areas.

A top hat lintel 34 of the form shown in Figure 5 is used, the interior dimensions being chosen so as to neatly fit over the fins 30 and to extend into the cavity.

A suitable window is installed having a peripheral frame 76 and a glazed window frame 77 fitted as the last step in Speci/400-499/449-499/45205 10 construction.

Figure 8 is a cross-sectional view in a vertical plane corresponding to Figure 7, but in this installation, being adapted to receive full length sliding doors in a sliding door unit having a peripheral frame 80 with tracks for sliding door units having a glazed frame 81. Figure 8 illustrates a balcony 82 at a lower level to the main floor 83 and illustrating how installation can be conducted to a typical reinforced concrete structure. In this case, the lower horizontal extrusion 84 retains only oo a single fin 30 and the drawing illustrates how a surface such as tiles 85 may be installed in a mortar 86.

15 Referring now to Figure 9, an alternative installation is 00 indicated wherein the extrusion 11 is installed in a cast concrete structure At least preferred embodiments of the invention offer 20 significant advantages which include the following.

1. The invention can be implemented in embodiments having strong frame sections with high strength corner connections to provide a rigid frame and, readily, gaskets can be included at the corners to provide weather proofing.

2. A frame can be produced which defines a permanent template for the required opening.

3. Factory production and precise required sizes for subsequent window or door installation can be provided.

4. The frame work can be used for a variety of constructions including cavity brick, brick veneer and masonry.

A frame formed from extrusions embodied in the invention can be light and easy to handle and once placed in the correct position, provides a vertical plum line for subsequent wall construction.

Speci/400-499/449-499/45205 11 6. Use of the present invention obviates the need for flashings and storm moulds for weather proofing. In particular, an embodiment using a double fin provides an excellent barrier against wind, water and sound.

7. Where a brick sill is required for a window, the fin of the preferred embodiment provides a backing edge for laying sill bricks which can be installed during normal brick laying, a great advantage over normal practice.

8. The preferred embodiment provides rebates on both the inner and outer surfaces so as to provide a neat and accurate shadow line for surface finishes or a rebate to take various finishes.

9. Embodiments of the invention lend themselves to 15 selected coatings and a protective film can be applied so that only after all the various trades such as brick work, carpentry, tiling, rendering and painting are complete, will the protective film be removed.

The invention lends itself to providing 20 selected profiles and in particular, with the use of aluminium, can still provide a solid or thick profile when desired to provide a similar appeal to conventional thick timber frames.

11. Use of the invention obviates brick ties, especially where the double fin design is used to position the frame in the centre of the cavity.

12. Because the frame is designed with precision and built in a factory, the window manufacturer and installer can be confident that precision is preserved and factory windows and door frames will fit precisely.

13. The use of the shadow rebates reduces time required by bricklayers, renderers, plasterers and painters; it is quicker and easier to form the quality finish required by architects.

14. Generally, work time on site is reduced and avoids multiple handling of window and door frames.

Particularly with embodiments using the Speci/400-499/449-499/45205 12 preferred lintel accessory, the builder has an easy method of bridging over openings and a single one piece metal lintel is provided instead of the traditional two lintels required for brick cavity wall construction. The integration of the sloping top section also sheds water and obviates the need for flashing.

16. Doors and windows can be installed from inside the building, thereby obviating the need for scaffolding.

.o* Speci/400-499/449-499/45205

Claims (13)

1. An extrusion for forming a frame defining an opening in a building structure including: a tubular body portion; a first side face having at least one fin extending away therefrom for engaging with an exterior wall element to define the relative location of the wall element and to provide weather sealing; and a second opposite side face adapted to receive and have attached thereto a window or door peripheral element and having a shoulder to define a location for an edge of the peripheral element and provide a weather seal at that 1 location. 0*. e

2. An extrusion according to claim i, wherein the tubular body portion is formed in aluminium with a .selected surface coating temporarily protected by a removable protection layer or coating.

3. An extrusion according to claim 1 or 2, wherein the body portion is generally rectangular tubular cross sectional form with two parallel integrally formed spaced fins arranged to define a wall cavity.

4. An extrusion according to any one of claims 1 to 3, wherein the shoulder is provided by a tubular extension portion arranged to form an undercut recess for confronting a peripheral element of a door or window to provide anchorage for a weather sealing strip.

Speci/400-499/449-499/45205 -14- An extrusion according to any one of claims 1 to 4, wherein the tubular extension has a rear wall parallel to the first side face but set back therefrom to a plane between the first side face and second opposite side face so as to provide a rebate from the inner wall of the structure for accommodating a finish such as a rendered finish or to accommodate plaster board.

6. An extrusion according to any one of claims 1 to wherein the edge of the extrusion adapted to be the outer edge includes a second tubular portion with a rear wall also in a plane generally between the first side face and the second opposite face to provide a rebate as either a shadow line or as a recess to also accommodate a surface finish such as render.

7. A polygonal frame for defining an opening for a door or window in a structure and including a plurality of lengths of extrusion according to any one of claims 1 to 6, formed with mitre jobs into a framework.

8. A frame according to claim 7, wherein the framework is provided with a protective layer whereby the protective eeo. layer can be left on the product until building work has 25 completed and then removed at the time of installation of eeeee the door or window component. ee

9. A method of building including using a framework having a multiplicity of extruded frame elements to define an opening in a building structure, the frame elements forming a permanent part of the structure to be built around the framework, the frame elements providing means for locating and connection to the structure with a weather seal, and means for locating and forming a weather seal within the zone defined within the framework for a peripheral frame element of a door or window unit.

Speci/400-499/449-499/45205 15 A method of building a structure having an opening in a wall for a door or window, the method including taking a rectangular frame according to either claim 7 or 8 and installing the frame in a vertical plane on a base structure formed in the building structure, constructing walls around and up to the opening with engagement of the wall structure with the rectangular frame with an inner face of the outer wall engaging a corresponding fin on the extrusion, the frame including spacings means to define a cavity in the wall and to provide an abutment for an inner wall structure and after completion of wall constructions and preferably after completion of surface finishing around the framework, installing a door or window peripheral frame to the framework.

11. An extrusion substantially as hereinbefore described with reference to any one or more of the attached Sdrawings. 20

12. A frame substantially as hereinbefore described with reference to any one or more of the attached drawings.

13. A method of building a structure substantially as hereinbefore described with reference to any one or more of the attached drawings. Dated this 25th day of March 2002 PERU PERUMAL GEORGE MADFOUNI By their Patent Attorneys GRIFFITH HACK Speci/400-499/449-499/45205