EP0521922B1

EP0521922B1 - Method of mounting a panel in a cavity wall

Info

Publication number: EP0521922B1
Application number: EP91906233A
Authority: EP
Inventors: Thomas John Wood
Original assignee: HEYWOOD WILLIAMS PLASTICS Ltd
Current assignee: HEYWOOD WILLIAMS PLASTICS Ltd
Priority date: 1990-03-06
Filing date: 1991-03-05
Publication date: 1999-08-18
Anticipated expiration: 2011-03-05
Also published as: CA2077534A1; EP0521922A1; EP0892141A3; EP0892141A2; AU7477391A; WO1991014066A1; DE69131536D1; GB9005010D0

Abstract

A retention component (30) and arrangement, particularly for use in securing a building panel such as a pre-assembled window in a wall opening, comprising a base (32) which carries on one face one or more teeth (34) and an abutment (36) for the panel, each tooth having a retention flank (34b).

Description

This invention relates to a method of mounting a panel in a cavity wall.
A typical panel is a window frame, specifically a factory pre-assembled double or triple glazed window unit. Such units are popular with users, but the fitting staff often find them difficult to manipulate into position in a prepared wall opening, especially in a multi-storey building in adverse weather.
Currently-used fitting methods require a pre-built wall opening, and this opening has to be accurately sized and shaped both to receive the respective unit and to permit the fitting staff to hold the unit in position until secured. Several fitting staff are usually involved.
A simple but reliable method is widely demanded.
In one prior proposal, a rectangular base frame having an outwardly directed flange is fed into a prepared (rectangular) wall opening from one side of the wall until the flange engages the internal wall surface around the opening, and a window frame also having an outwardly directed flange is fed into the opening from the outer side of the wall so as to telescope within the base frame and until its flange engages the external wall surface around the opening; the window frame is held in the base frame by resilient tabs carried either by the base frame or the window frame and which inter-engage with respective facing grooves on the window frame or base frame. It is suggested that by providing a plurality of grooves this proposed arrangement can be used for various wall thicknesses, with the respective flanges sandwiching the brickwork around the wall opening, but to help ensure that the desired tight retention is obtained a resilient sealing strip positioned between the window frame flange and the outer wall surface around the opening can be compressed a distance substantially in excess of the spacing between successive grooves.
The above proposed arrangement has however a number of disadvantages in that (a) there needs to be simultaneous access available from both sides of the wall opening, which may not always be possible whilst building is continuing; (b) the prefabricated window frame needs to be manipulated into the opening at the same time as the base frame, requiring extra fitting staff; (c) the telescopic arrangement assumes a uniform wall depth all around the opening, typically requiring the bricklayer accurately to lay the surround brickwork.
In AT-A-349718 there is described a base frame set into a wall, and made up of retention components having a set of teeth against which a resilient member carried by a window frame engages to facilitate fitting. The blind frame is fitted into a solid brick wall.
In NL-A-8301027 there is described a fitting strip to facilitate installation of a window or door frame in a cavity wall. The strip has a tooth-like formation to facilitate press-fitting of the window or door frame. On the opposite side of the fitting strip to the tooth-like formation is a pair of parallel flanges which locate within the cavity of a cavity wall.
We now propose a method which avoids or reduces some of the above disadvantages.
We therefore propose a method of mounting a panel in an opening in a newly built cavity wall using a rectangular former about which bricks and blocks can be assembled to form the wall and said opening therein, and into which former the panel can subsequently be press-fitted, wherein said former is made of retention components, and wherein a said retention component has:
a base;
a plurality of teeth projecting from one face of the base, said teeth having retention flanks;
an abutment projecting from the same face of the base as the teeth, said abutment projecting further from said base than the teeth;
and an extension part projecting from the opposite face of the base to the teeth and the abutment, and being of width to span said cavity; wherein the base extends beyond both sides of the extension part;
and wherein the panel has one or more resilient retaining fingers integral with or secured to the panel;

making said rectangular former;
assembling the bricks and blocks about the former as leaves of a cavity wall, with the bricks which terminate at the reveal being placed against one side of the extension part and against said base, and with the blocks which terminate at the reveal being placed against the other side of the extension part and against said base;
and inserting the panel in place within the opening by pressing it towards and against the abutment; wherein said one or more resilient retaining fingers of the panel are thereby engaged with said teeth to secure the panel in place.

Preferably the teeth are angled toward the abutment; so that if saw-teeth, then the one flank (the retention flank) will be substantially parallel to the plane of the abutment whilst the other flank (the over-ride flank) will be in a plane intersecting the abutment plane. Usefully all of the teeth are of uniform height i.e. a common projected distance from said one side of the base; but some or all of the teeth may be of different heights to suit the resilient retaining fingers. It will be understood that for ease of production the teeth will preferably extend the length of a retention component (laterally of the panel insertion direction), and will usefully be in the form of angle blades.
Each upstanding (saw-tooth) retention flank is firmly engageable by a respective resilient retaining finger, typically one finger or a group of fingers integral with or secured to a pre-assembled glazed window unit, to provide an improved retention arrangement for the unit; during installation the retaining fingers can ride over the angled (over-ride) flank of the saw-teeth.
During the method the window panel is inserted towards and usually up the abutment, but cannot be fed past the abutment, which is preferably spaced inwardly of the building, and which can also provide a plaster edge, and a plaster "height level".
Suitably, a retention component has mitred ends whereby it is joined to similarly shaped components, to form the rectangular structure providing a former about which the bricks and blocks can be built; this method avoids the need for a temporary framework as conventionally used to define the opening, and which is removed when the brickwork is completed (perhaps leaving an opening of different dimensions to that of the panel, which may only be brought on site later).
Usefully, the abutment can locate a resilient sealing gasket, permitting easy finishing of a fitted window, with the gasket concealing the plaster edge. If the plaster shrinks after the window has been fitted, any gap between the plaster edge and the abutment is not visible. Draughts through the gap can be prevented. The gasket can flex to follow (fitted) window movement.
An advantage of our method is that not only can the retention arrangement of the invention locate a panel such as a window unit reliably in the opening, but the extension piece itself can provide damp proofing and draught sealing of the cavity between the outer brickwork and inner blockwork i.e. there can be cavity closing, cavity sealing, and damp proofing.
Our invention will be further described by way of example by reference to the accompanying schematic drawings in which:-

Fig. 1: is a plan view of a fastening device suitable for use in the method of the present invention;
Fig. 2: is a view (not to scale) on the line II-II of Fig. 1;
Fig. 3: is a view (not to scale) on the line III-III of Fig. 1;
Fig. 4: is of an end view of a retention component suitable for use in a method of the invention;
Fig. 5: is an end view of an alternative embodiment of retention component for use in a method of the invention;
Fig. 6: is an end view of another alternative embodiment to that of Fig. 4;
Fig. 7: is a plan view of the embodiment of Fig. 6; and
Fig. 8: is a schematic front elevation of a fitted former constructed from retention components shaped according to Fig. 4 or Fig. 5.

The fastening device 10 shown in Figs. 1, 2 and 3 is the subject of our European Patent 356430B. It is formed from 0.4mm thick hard rolled stainless steel, in this embodiment from a rectangular blank of 80mm x 35mm; it comprises a flat plate section 12 and two resilient retaining fingers 14 and 16 which extend generally upwardly (as seen in Fig. 2) from the plate section 12, and to the same side thereof. Between the fingers there is retained an intermediate portion 19, in the same plane as the flat plate section 12, and which in an alternative embodiment has a nailing hole i.e. of smaller diameter than screw holes 18. The fingers 14, 16 have their engagement tips 15, 17 axially (i.e. upwardly as seen in Fig. 1) and laterally offset.
The resilient retaining finger 14 is in the form of a tongue, provided by a substantially planar strip punched from flat plate section 12 and which is angled at 60 degrees to the plane of plate section 12, and in this embodiment reaches at its tip 15 a height of 10mm above the plane of plate section 12.
The second resilient retaining finger 16 is also in the form of a tongue, provided by a strip angled from plate section 12, to a height at its tip 17 of 9mm above the plane of the plate section 12. The finger 16 comprises two sections 16a and 16b. The first section 16a is at 45 degrees to the plane of plate section 12, and the second section 16b, which is integral with the first section 16a, is at 85 degrees to the plate section 12.
Two holes 18, aligned with resilient retaining fingers 14 and 16, are formed through the plate 12; in use, fastening means such as a countersunk screw or (less preferably) a nail can be passed through each hole 18 to fix fastening device 10 to a surface, such as to the surface of a window reveal.
The retention component 230 of Fig. 4 has a base 232, a plurality of saw-teeth 234 projecting from one side of the base (i.e. as seen in the view of Fig. 4 generally upwardly, but inwardly of the opening in use) and providing closely-spaced adjacent grooves each shaped lockingly to receive a resilient retaining finger from a window or equivalent frame, and an abutment 236 extending from one longitudinal edge of the base and projecting further from said one side of the base than the saw-teeth 234. The teeth 234 are all to one side of the abutment 236 i.e. that side first met when a window frame is inserted. The saw-teeth are defined by an over-ride flank angled to intersect the plane of the abutment and a retention flank parallel to the plane of the abutment.
On the opposite side of the base 232 to the saw-teeth and the abutment is an extension part 200, an integral part of the retention component in this embodiment. Extension part 200 is of hollow extruded construction, with strengthening ribs 205; alternatively the parts can be separately extruded, and heat welded or otherwise secured together.
In this embodiment abutment 236 has a rearward angled surface 237, which provides a plastering level for plastering section 235. To help key the plaster, surface 237 is ridged.
Other embodiments of retention component suitable for use in the present invention are shown in Figs. 5, 6 and 7. The embodiment of Fig. 5 has a stiffened extension part of somewhat different type to that shown in Fig. 4. The embodiment of Fig. 6, also shown in Fig. 7 in plan view, has differently shaped teeth, and a different design of extension part, to those shown in Fig. 4. The extension part has recesses on opposed sides thereof. Typical cavity widths are 38mm, 48mm, and 64mm. Spacers can be fitted to one or both sides of the extension part, by way of heads thereof received in one or both of the recesses. The recesses are also suitable for locating brick ties, when required.
In the embodiments shown the teeth are not all identical; in other designs all of the teeth of a retention component may be identical saw-teeth.
The retention components of Figs. 4-7 are suitable for a "new-build" opening, using methods in accordance with the present invention. With reference to Fig. 8, the retention components will be cut to length, and will be connected (as by welding or adhesive or corner brackets) to similar cut lengths to form a rectangular frame, around which the bricks 60 and blocks 70 can be built to form a window opening 203 of pre-selected dimensions and size, with the rectangular former (assembled from four retention components) locked permanently in position in the window opening, and itself defining the wall opening 203. The bricklayer will typically lay a line of bricks 60 and blocks 70 to a selected height, and will then lay a further layer of either the bricks or blocks, position the extension part 200 of a preformed rectangular former 201 against the extra layer, and then clamp the extension part 200 in position by laying further bricks or blocks so as to sandwich the extension part 200, as seen in Fig. 8.
As the bricks and blocks continue to be laid, the retention component 230 is located in position in the cavity or gap between the outerwall bricks and innerwall blocks.
A window frame (not shown) but suitably pre-formed and possibly double-glazed, and fitted with resilient fastening members, suitably of metal and shaped as shown in Figs. 1-3, is now fed from outside the building inwardly towards abutment 236 and is permanently retained by the resilient retaining fingers 14, 16 riding over and then engaging with respective retention flanks of saw-teeth 234 to effect retention.
One advantage of the described arrangement is that the bricklayer can lay the bricks 60 and blocks 70 for a cavity wall structure without needing the glazier to be present; another advantage is that the window fitter (and glazier if a non-glazed frame is fitted) can attend upon the opening merely from the outside of the building without requiring anyone inside to hold the retention component; and a yet further advantage is that once the window is fitted, the plasterer can continue to lay plaster internally of the building, often using the abutment 236 as a height guide and end stop.
The saw-teeth 234 can if required provide an interim fitting stage, wherein the window frame is temporarily held whilst being checked for alignment, before being (squarely) pressed rearwardly towards abutment 236 for respective tab engagement with the upstanding (rear) flank of a tooth 234.
Although for clarity a gap is shown (Fig. 5) between the extension part and the bricks and blocks, in practice the bricklayer will seek to avoid these gaps. However the retention component can if required be laid on a bed of mortar or equivalent, or the gap can be sealed by a known resilient sealing compound.
As seen in the plan view of Fig. 7, plastering section 235 has aperture 237, whereby in use the plaster can key through the retention member directly onto the brickwork, e.g. blocks 70.
In an alternative method a fastening device 10 may be located by way of flat plate section 12 between a pair of surfaces 204, 206, or 208, 210, or 212, 214 (Fig. 5) with the upstanding tips 15, 17 of the resilient retaining fingers directed generally towards the interior of the building i.e. towards the abutment, to engage outwardly directed ribs in the frame and so retain the window frame, in this embodiment by their serrated tip(s) as disclosed in European Patent 356430B; but alternatively with tips 15, 17 engaged in one or more spaced recesses in the cooperating frame edge. The surfaces 204, 206 will have a height substantially equal to the thickness of flat plate section 12 i.e. 0.05mm. The pairs of surfaces 204, 206 and 208, 210, and 212, 214 have facing projections 216 (Fig. 4) at their upper (inward) ends, to retain the fastening device 10 until the window frame is inserted; fastening device 10 will be of a hard material e.g. metal, which can be pressed past the facing projections 216, usually of a plastics material, and which thereafter spring back towards their initial positions.

Claims

A method of mounting a panel in an opening (203) in a newly built cavity wall using a rectangular former (201) about which bricks (60) and blocks (70) can be assembled to form the wall and said opening therein, and into which former the panel can subsequently be press-fitted, wherein said former is made of retention components (230), and wherein a said retention component has:

a base (232);

a plurality of teeth (234) projecting from one face of the base, said teeth having retention flanks;

an abutment (236) projecting from the same face of the base as the teeth, said abutment projecting further from said base than the teeth;

and an extension part (200) projecting from the opposite face of the base to the teeth and the abutment, and being of width to span said cavity; wherein the base extends beyond both sides of the extension part;

and wherein the panel has one or more resilient retaining fingers (14, 16) integral with or secured to the panel;

the method comprising the steps of:

making said rectangular former;

assembling the bricks and blocks about the former as leaves of a cavity wall, with the bricks which terminate at the reveal being placed against one side of the extension part and against said base, and with the blocks which terminate at the reveal being placed against the other side of the extension part and against said base;

and inserting the panel in place within the opening by pressing it towards and against the abutment;

wherein said one or more resilient retaining fingers of the panel are thereby engaged with said teeth to secure the panel in place.
A method according to Claim 1, wherein the extension part extends into the cavity so as to function as a damp-proofing member, a draught seal and a cavity closure member.
A method according to Claim 1 or Claim 2, wherein the blocks are built up to form the inner leaf of the cavity wall, and wherein the abutment is adjacent the inner leaf and provides a plastering edge.
A method as claimed in any preceding claim comprising the preparatory step of securing fastening devices to the panel, said fastening devices providing said resilient retaining fingers.
A method as claimed in any preceding claim, wherein the teeth are angled towards the abutment.
A method as claimed in any preceding claim, wherein the teeth are of uniform height.